hilux (double cab) - toyota-tech.eu · hilux (double cab) hard tonneau cover with high over bar...
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Hilux (Double Cab) Hard tonneau cover with High over bar Installation Instructions
Model year: 2015/04
Vehicle code: GUN1***-D***HW
Part number: PW3B0-0K001 High over barPW3B1-0K008 Hardtonneaucover(grainedfinish)PW3B1-0K028-** Hardtonneaucover(painted)PW3B1-0K101 Hardtonneaucover-sidecovers(grainedfinish)PW3B1-0K093-** Hardtonneaucover-sidecovers(painted)
Manual reference number: AIM 003 426-1
1x
6x4x1x
4x8x
PW3B0-0K001 High over bar
A
E D1x I
1xB 1x C
F
G H
M10x1.5x30
M8x1.25x25
M6x1x30
Manual reference number: AIM 003 426-1 2 of 31
Revision recordRev. No. Date Page Picture Update New Deleted steps
1 10.05.2016 All All X
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 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
LHM8 RH
2x
M8X20 M8 M8 M8 M8 M8 OD25 ID8.3
M8X35
Manual reference number: AIM 003 426-1 3 of 31
Ø 30mm
Ø 3mmØ 5mmØ 9mm
A:Sikkens® primer surfacer EP II
B:Sikkens® primer surfacer EP II Hardener
A:PRIMERB:ACTIVATOR
A:Standox® Etching Adhesion Primer 020 16167
B:Standox® Etching Adhesion Activator 020 16168
or
Teroson Multi-WAX Spray796107
Würth 0893 081-E/B
WAX
4 mm
Ø 10mmØ 12mmØ 13mmØ 17mm
Ø 12mmØ 13mmØ 17mm
3M 751
M8
SikaflexRef.: 555
MSDS
TDS
40°C
18°C
Manual reference number: AIM 003 426-1 4 of 31
x2
0 mm
1
2
A A
Manual reference number: AIM 003 426-1 5 of 31
2
1
L
N
L
6
4
2x
10mm
AF
2
3
3
X
X
1 CLEANER / DEGREASER
5
Manual reference number: AIM 003 426-1 6 of 31
3
N
X
L
AF
U
V
1
2x
Ø 3 mmØ 5 mm
3 10 mm 2
6x
Ø 3 mmØ 5 mm
5 10 mm 4
2x
1 2
6x
Manual reference number: AIM 003 426-1 7 of 31
5
4
L
WAX
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 003 426-1 8 of 31
6
3
1
2x
10mm
2
8 Nm
S
Manual reference number: AIM 003 426-1 9 of 31
7
N
X
U L
V
30 mm 30 mm
x81
2
3
1
2
3
4
SikaflexRef.: 555
SikaflexRef.: 555
Manual reference number: AIM 003 426-1 10 of 31
8
M M
M M
M
2x 2x
2x
8x
LH = RH
1
2
PROTECTIVECLOTH
BOX
BOX
BOX
BOX
6x
4 mm
Manual reference number: AIM 003 426-1 11 of 31
10
9
K
AG
AA
Z
AB
PAF
A
F
2x
2x
6x
4 mm10 Nm
S
1
1
2
3
Manual reference number: AIM 003 426-1 12 of 31
12
11
D
D
F
A
B
C
K
E
I
K
6xF
V
V
U
U
W
W
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
Manual reference number: AIM 003 426-1 13 of 31
13
K
K
K
K
1
x14
2
1(5) mm
Manual reference number: AIM 003 426-1 14 of 31
14
3
3
1
2
14x
Ø 3 mmØ 5 mm
Ø 10 mm
2 10 mm 1
WAX
3 67
8 930 min.
21°C
10
21°C
5
10 min.
MAX 15 min.2 8
4 3mm
3mm
CLEANER / DEGREASER
Manual reference number: AIM 003 426-1 15 of 31
16
15
2
2
3
4
LH = RH
10 mm
1
SikaflexRef.: 555
Ø6mm
CLEANER / DEGREASER
Manual reference number: AIM 003 426-1 16 of 31
17
6x
12 mm
1
2
8x
13 mm
Manual reference number: AIM 003 426-1 17 of 31
19
18
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 003 426-1 18 of 31
20
S
32
1
SikaflexRef.: 555Ø6mm
4
5
30mm
30mm
CLEANER / DEGREASER
Manual reference number: AIM 003 426-1 19 of 31
21
O
SikaflexRef.: 555
Ø6mm
Manual reference number: AIM 003 426-1 20 of 31
23
22
J
4x
4x
18 Nm13mm
SEC.
1
2
13mm
S
Manual reference number: AIM 003 426-1 21 of 31
25
24
J
L
XAA
Z
AB
A
X≠X
SEC. B-B
A BB
SEC. A-A
X X
X=X
SEC. B-BSEC. A-A
X X
X
LH/RH
X=X
Manual reference number: AIM 003 426-1 22 of 31
26
K
J
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 003 426-1 23 of 31
28
27
K
X=X
X
LH/RH
X=X
X=X
(X) mm
Manual reference number: AIM 003 426-1 24 of 31
29
4x
12 mm
SEC.
6x
18 Nm12mm
4x
18 Nm13mm
4x
18 Nm13mm
4x
22 Nm17mm
8x
18 Nm12mm
2x
8 Nm10mm
LH = RH
1
2
3 4
5
6
12mm
12mm
S
S
S S
SS
Manual reference number: AIM 003 426-1 25 of 31
31
30
Q
AD Z Y
R
4x
4 mm
44x
4 mm6 Nm
65
1 2
3
CL CL
LH=RH LH=RH
LH RH
10mm
S
2
4x
12 Nm12mm
1
3
2
ClickCL
1
ClickCL
1
ClickCL
S
Manual reference number: AIM 003 426-1 26 of 31
32
33
33
OWNER’S MANUAL
CABLE ADJUSTMENT
4x
4 mm
4
5
1 2
3
CL CL
LH=RH LH=RH
LH RH
10mm
Model year: Vehicle code:
Part number: High over bar Hard tonneau cover (grained Hard tonneau cover (painted) Hard tonneau cover-side covers (grained finish)
2015/04 GUN1***-D***HW PW3B0-0K001 PW3B1-0K008 PW3B1-0K028- ** PW3B1-0K101 PW3B1-0K093- ** Hard tonneau cover-side covers (painted)
KG
KG
KG
CAUTION
4x
4 mm6 Nm
6
S
Manual reference number: AIM 003 426-1 27 of 31
Manual reference number: AIM 003 426-1 28 of 31
CHECK SHEET
VIN n°
Model / Year Hilux (Double Cab)2015/04
Hard tonneau coverwith High over bar
SEC.
LH = RH
1
3
2
Serial NumberCLICK
Click
1
118Nm
4x6Nm
4x12Nm
4x
2
3
2 3 ...S
BLH RH
A BA
P/N = OK
Owner’s
manual
=A =B
Manual reference number: AIM 003 426-1 29 of 31
1
3
2
4
6
5
5
7
7
Serial NumberCLICK
S
8
88
LH = RH
9
Click
1
18Nm
2x22Nm
2x22Nm
2x
2
3
2 3 ... BLH RH
A BA
4 18Nm4x
18Nm6x
18Nm4x
5
6
18Nm8x7
10Nm
8Nm2x
6x8
9
LH = RH
Manual reference number: AIM 003 426-1 30 of 31
Installation Date: Stamp:Technician Name & Signature:
. . / . . / . . . .
3x
= OK
= OK = OK
1
1 2
LH = RH
2 2xClick
1xClick
Manual reference number: AIM 003 426-1 31 of 31