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


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-*


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


1

N

AF

2

3

3

Y

1 CLEANER / DEGREASER

Y

0 mm

5

4

6 2x

8mm8 Nm


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


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


5

2

1

2x

8mm8 Nm


6

N

T

U L

V

S

3

x81

2

1

2


7

M M

M M

M

2x 2x

2x

8x

1

2

PROTECTIVECLOTH

BOX

BOX

BOX

BOX

6x

4 mm


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


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


12

11

K

K

K

K

V

V

U

U

W

W

1

x14

2

1(5) mm


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


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


16

LHS=RHS

6x

12 mm

1

2

8x

13 mm


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


19

S

32

1

Ø6mm

or

SikaflexRef.: 555

Butyl


20

O

SikaflexRef.: 555

Ø6mm


22

21

J

4x

4x

18 Nm13mm

SEC.

1

2

13mm


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


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


27

26

K

X=X

X

X=X

X=X

(X) mm


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


30

29

Q

AD Z Y

R

S

4x

4 mm

1

2

4

3

1mm

4x

4 mm

5


31

1

2

4x

12 Nm12mm

2

ClickCL

1

ClickCL

1

ClickCL


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.


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


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


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


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


hilux (double cab)

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