toyota hilux double cab - sr / sr5 canopy, a-deck and j ... fleet cnpy.pdf · toyota hilux double...

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CP0061

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

Installation Time:1.5 Hours (Approximately)

Without Bed Liner fitted2 Hours (Approximately)

With Bed Liner fitted

CANOPYINSTALLATION INSTRUCTIONS

Clean Canopy with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

RECOMMENDED TOOL LIST - (Not Supplied in Kit)• Loctite 243 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 - 0-20Nm• Angle Grinder (Medium Size)• Disc Sanding Attachment & Pads for Angle Grinder• Hacksaw or Jigsaw• Wire Crimping Tool• Ø30mm Holesaw

• Allen Keys (Ball Ended Type)• Engineers Set Square• Non Permanent Marker• Masking Tape• Cleaning Cloths / Rags• Steel Rule and Tape Measure• Scissors (Sharp)• Knife (Sharp)• Squeegee• Metal Primer• Electric Drill• File or Deburring Tool• Draw Wire• Hammer & Centrepunch• Ø3mm Ø5mm Ø9mm Ø10 and Ø12mm Drill Bit• Rivet Gun for Stainless Steel Rivets• Torch

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

This Canopy is designed to suit the Double Cab (4x2 & 4x4) SR & SR5 Hilux.Sports Bars MUST be removed & returned to Customer with all hardware components if required.Cabin Guards MUST be removed & discarded.This Fitting Instruction where a Ute Liner is referred to, is based on -Toyota Genuine Over Rail Ute Liner Accessory Part No’s. :-PZ053-0K003 (With Cabin Guard) PZ053-0K073 (Without Cabin Guard) only.

Toyota Hilux Double Cab - SR / SR5Canopy, A-Deck and J-Deck - June 2011 Onwards

With and Without Ute Liner

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/failure of components.• Recommend installation by 2 people. (4 people will be required to lift Canopy)

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CP0061TOYOTA HILUX - CANOPY

PARTS CHECK SHEET TOYOTA HILUX CANOPY

CanopyQty - 1

PARTS IN MAIN CARTON

Fitting KitQty - 1

Lock Keys(Attached toCanopy InternalRear Door Handle)Qty - 2

PARTS IN FITTING KIT: KIT032560

PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0050)

Cable Ties(5) Long 600mm(7) Short 200mmQty - 12

Blade FuseHolderQty - 1

Ring terminal8mm internal dia.Qty - 2

Corrugated Tube5mm internal dia.100mm longQty - 1

Clear AbrasionTape Roll48mm Wide(TAPE0611-1)Qty - 1

Foam Tape5.5mx20x6mm(TAPE0386)Qty - 1

Screw M6x25Hex Head SS304(SCRW0868)Qty - 16

Front Tub SpacerExtrusion(ALUM0038-7)Qty - 1

RustInhibitor

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.

Tape 4026 GHBWH12x1700mmx 1.14Thick Roll(TAPE0615)Qty - 1

Rivet SS304ST\ST 6-6(FAST0505)Qty - 12

Long RivetSS304ST\ST 6-12(FAST0613)Qty - 4

Rail BracketBacking Plate(CLIP2831PC)Qty - 6

Base Rail MountingBracket(CLIP2890PC)Qty - 6

FittingInstruction

BlackenedM8x30 HexHead Screw(SCRW0846)Qty - 6

Blackened M8Flat Washer17mm SS304(WASH0171-1)Qty - 6

M6 Spring WasherSS304(WASH0103)Qty - 16

Blackened M8Spring WasherSS304(WASH0152-1)Qty - 6

Alcohol Wipe(MISC0052)Qty - 4

Rust InhibitorSatchel(MISC2776)Qty - 2

Primer Stick(MISC1365)Qty - 4

Vehicle WiringPatch Harness Kit(LOOM0050)Qty - 1

FittingInstruction(FIT-CP0061)Qty - 1

M6 NutSS304(NUTS0161)Qty - 16

5 Amp BladeFuseQty - 1

Clear abrasionTape Tub CornerDie Cut Right Hand(TAPE0627-RH)Qty - 1

Clear abrasionTape Tub CornerDie Cut Left Hand(TAPE0627-LH)Qty - 1

M8x25 Allen KeyButton Head ScrewSS316(SCRW0623)Qty - 6

M8 Flat WasherOD. 17mm SS(WASH0171)Qty - 12

M8 NylocNut SS(NUTS0242)Qty - 6

M6 Flat WasherOD. 19mm SS(WASH0169)Qty - 32

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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 13.IF FITTING TO AN ‘A’ DECK SR5 VEHICLE, GOT TO STEP 01. IF FITTING TO ‘J’ DECK SR VEHICLE GO TO STEP 68

Remove the six (6) 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.

Using cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the canopy, and a piece betweenthe tub and cabin as a protection sheetwhile removing the cabin guard.(ref. diagram2).

2.

Diagram: 2 - PROTECT VEHICLE SURFACES

Apply 200mm lengths of overlappingmasking tape to the top and side of thetub rail, up to and around the cabin guardas shown.Recommended: Fit a 2mm thick steelplate as a sacrificial grinding plate (Notsupplied in kit), next to the cabin guardas shown, repeat process for the otherside of the vehicle. (ref. diagram3).

3.

Diagram: 3 - SECURE GRINDING PLATE

Diagram: 1 - REMOVE SPORTS BAR & HARDWARE

FITTAPE

RECOMMENDEDFIT SACRIFICIALGRINDING PLATE

1

2

POSITIONCARDBOARD

TUB AND CABINPROTECTION MATS

CABIN GUARD

REAR TUBE

SHAKE PROOFWASHER

MOUNTING FOOTWASHER

SPACERNUT

PLATE

BOLT UTE BODY

REMOVEHARDWARE

2

1

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Secure the sacrificial grinding plate (notsupplied in kit) to the tub rail by coveringit with masking tape as shown.Repeat process for the other side of thevehicle. (ref. diagram4).

4.

Insert a suitable protective timber boardof adequate thickness between thecardboard and cabin guard as shown.IMPORTANT: To avoid accidentaldamage to the vehicle, the timber boardMUST be used when ever cutting of thecabin guard is undertaken.(ref. diagram5).

IMPORTANT: Ensure that the vehicle’s(paint work, glass, etc...) is adequatelyprotected before removing the cabinguard.Using a medium sized angle grinder,partially cut through the rear and sidefaces of the LH outer cabin guard bar,taking care not to damage vehiclesurfaces.Repeat process for the RH side of thevehicle, ensuring the protective timberboard is repositioned behind the RH outercabin guard bar. (ref. diagram6).

5.


6.

Diagram: 6 - REMOVAL OF CABIN GUARD


PARTIALLY CUT THROUGHOUTER CABIN GUARD BARS

SECURESACRIFICIAL GRINDING

PLATE WITH TAPE

INSERTTIMBER BOARD

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IMPORTANT: Ensure the protectivetimber board is repositioned behind each of the centre support bars beforecutting.Using a medium sized angle grinder,completely cut through the three (3)centre support bars at the base, flush tothe front tub rail, taking care not todamage vehicle surfaces. (ref. diagram7).

7.

IMPORTANT: Ensure the protectivetimber board is repositioned behind the outer cabin guard bars beforecutting.Two people are required to completethis step, one person will need tosupport the cabin guard and prevent itfrom damaging the vehicle while theother person finishes cutting throughthe cabin guard bars completely.Using a medium sized angle grinder,completely cut through the LH and RHouter cabin guard bars, flush to thegrinding plates.Carefully remove cabin guard fromvehicle and discard. (ref. diagram8).

IMPORTANT: Ensure the protectivetimber board is repositioned to each bar location before cutting.Take care to prevent damage to vehicle.Using a medium sized angle grinder,carefully cut away any remaining metalnot flush with the tub rail.Remove sacrificial grinding plates andall masking tape. (ref. diagram9).

8.


9.

Diagram: 9 - PREPARE VEHICLE SURFACES


1

2

INSERTTIMBER BOARD

COMPLETELY CUT THROUGHCENTRE SUPPORT BARS

1

2

SUPPORTCABIN GUARD

COMPLETELY CUT THROUGHOUTER CABIN GUARD BARS

1

2

GRINDAWAY ANY REMAINING

METAL NOT FLUSHWITH THE TUB

REMOVEGRINDING PLATES

& TAPE

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Using a file / de-burring tool, remove allburrs and sharp edges from cabin guardand tub rail surfaces previously cut withthe angle grinder. (ref. diagram10).

10.

Remove all timber boards and cardboardprotection mats from the vehicle.Retain cardboard tub floor protection matfor use later during the fitment.Using compressed air, completely blowout all metal filings, swarf etc... in the tubfloor. (ref. diagram11).

Using a suitable metal primer, paint overand completely cover all bare metalsurfaces previously cut and deburred.(ref. diagram12).

11.

Diagram: 11 - CLEAN VEHICLE SURFACES

12.

Diagram: 12 - PRIME VEHICLE SURFACES


1 REMOVETIMBER BOARDS& CARDBOARD

PROTECTION MATS

DEBURRALL SURFACES AROUNDCUT CABIN GUARD BARS

2

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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).

13.

Diagram: 13 - CLEAN & DRY INSTALLATION AREAS

POSITIONCARDBOARD TUBPROTECTION MAT

1

2

14. Apply masking tape across the front of theute liner as per highlighted surfacesacross the front of the ute liner mark a line8mm down from the top face.Measure and mark a line at the centre ofthe ute liner and then 760mm outboardeach side of the centreline as shown.Apply masking tape in the rear LH side topcorner of the ute liner, mark two lines, onevertical at 45mm from the edge of the liner and one at 25mm up from the horizontalstep in the liner. (ref. diagram14).

Diagram: 14 - MEASURE & MARK UTE LINER

15. Remove and retain the ute liner andattachment hardware from the vehicle.(ref. diagram15).

Diagram: 15 - REMOVE UTE LINER

REMOVE & RETAINUTE LINER & ALL HARDWARE

PROCEED FOR VEHICLES WITH A UTE LINER FITTED.

IF VEHICLE IS FITTED WITH A UTE LINER, PLEASE PROCEED WITH STEPS 14IF VEHICLE IS NOT FITTED WITH A UTE LINER, PLEASE PROCEED TO STEP 17

APPLYMASKING TAPE

0mm 10 20 30 40 50 60 70 80 90

8mm

MEASURE & MARKA LINE ACROSS THE LINER

8mm DOWN FROM THE TOP FACE

2

MEASURE & MARKCENTRELINE OF UTE LINER

1

4

3

760mm TOCENTRE OFUTE LINER

CROSS SECTIONTHROUGH FRONT

OF UTE LINER

8mm

1

VEHICLE TUB NOT SHOWN FOR CLARITY

25mm

45mm

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16. Using a jigsaw or similar, carefully cut thefront top section of the ute liner off usingthe lines marked 8mm down from the top.Remove all burrs and sharp edges with afile or deburring tool or angle grinder withdisc sanding attachment. Using a 3mm drill put a pilot hole in the rearLH side of the liner where the hole centehas been marked. Redrill with a 30mm holesaw. When complete remove all masking tape from the ute liner. (ref. diagram16).

Diagram: 16 - CUT UTE LINER FRONT PART AWAY & DRILL REAR HOLE

DRILL OUT THE Ø3MMPILOT HOLE IN THE

UTE LINER TO Ø30MM USING HOLE SAW

CUT OUT and DEBURRTHE FRONT MARKED

AREA CAREFULLY

1

17. Apply masking tape to the back rear cornerof the tub, mark out position of hole.Pilot drill hole Ø3mm and drill out to Ø9mmhole. Apply rust inhibitor to the hole.(ref. diagram17).

Diagram: 17 - DRILL WIRING HOLE IN REAR LH SIDE TUB 18. Refit the ute liner and attachment hardware

to the vehicle. (ref. diagram18).

Diagram: 18 - REFIT UTE LINER

REFITUTE LINER & ALL HARDWARE

1

2

1

40mm

38mm

30Ømm

RustInhibitor

FOR VEHICLES FITTED WITH OR WITHOUT A UTE LINER.

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NOT SUPPLIED

FRONT TUB SPACER EXTRUSION

19. 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 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. diagram19).

Diagram: 19 - FIT 3M DOUBLE SIDED TAPE 12x1700mm

20.

21.

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. diagram20).

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 rearwardand down on the front tub spacer extrusionalong the length to ensure maximumadhesion of the foam tape. Clean anyexcess silicon off using isopropyl alcohol.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. diagram21).

Diagram: 21 - FIT RAIL EXTRUSION TUB SPACER

Diagram: 20 - APPLY SILICON TO THE TUB SPACER

FRONT RAIL

FRONT OF THE VEHICLE

TOP VIEW OF TUB

TAPE COVERSHALF OF THE HOLE

APPLYDOUBLE SIDED 12x1700mm ROLL(TAPE0615) ACROSS FRONT RAIL

1

4

POSITION DOUBLE SIDED TAPE AGAINST 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

APPLY12mm BEAD OF SILICON

TUBSPACER(ALUM0038-7)

TAPE

FRONT OF CAR

VIEW FROM TOP OF VEHICLE

CROSS SECTIONTHROUGH FRONT RAIL

SILICONFRONT RAILOF TUBUTE LINER(IF FITTED)

2

3

5 1 2 MEASURE & MARKCENTRE LINE OF TUB SPACER

MEASURE & MARKCENTRE LINE OF FRONT RAIL

= =3

4

1222.5

SILICON

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22. Apply masking tape to the side of the uteliner as shown and mark line 22mm downfrom top face. Measure and mark three centre lines starting from the front edge of the tub rail spacer extrusion just fitted.First at 282mm, then 742mm and 1192mm. Do the same for the other side of the uteliner. (ref. diagram22).

0mm 10 20 30 40 50 60 70 80 90

24. Remove the ute liner and attachment hardware from the vehicle.(ref. diagram 24).


REMOVEUTE LINER & ALL HARDWARE

1

20mm

Diagram: 22 - MEASURE & MARK UTE LINER SIDE HOLES ON VEHICLE

22mm

282mm

742mm

1192mm

APPLYMASKING

TAPE

1

2 MEASURE & MARKHOLES CENTERS


23. Using a Ø3mm drill with a drill stop set to adepth of 20mm, carefully drill out the 3positions on each side (total 6 places),through the bed liner and through the sheetmetal tub return flange.Redrill each of the 6 holes to Ø9mm with adrill set to a depth of 20mm. (ref. diagram23).

Diagram: 23 - DRILL HOLES IN THE UTE LINER ON VEHICLE

1

DRILL THE HOLESWITH Ø3mm DRILL AND Ø9mm DRILL

VEHICLE NOT SHOWN FOR CLARITY

TOP VIEW OF LH CORNER OF TUB


STARTMEASUREFROM FRONTEDGE OF TUBRAIL SPACER

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26. Screw M8 bolt into the backing plate (CLIP2831PC) and fit into the 9mm hole in the tub.Secure the backing plate with an M8 nut. This is a temporary procedure to ensure the rivet holes are drilled in the correct location.Using a drill with a drill stop set to a depthof 20mm, carefully drill the two (2) markedhole positions to Ø5mm through the backingplate and sheet-metal tub return flange as shown. Remove the backing plate from the tub and uscrew the M8 screw from the backingplate.Remove all burrs and sharp edges fromdrilled holes. Apply rust inhibitor (MISC2776)to all drilled holes.Repeat process for all 3 places on the sameside than repeat on the other side of the vehicle. (ref. diagram26).Diagram: 26 - DRILL BACKING PLATE RIVET HOLES

27. Orient and fit the backing plate to theinside of the sheetmetal tub return flangeand secure with two (2) short rivets(FAST0505) as shown.Repeat process for all 3 places on the sameside, than repeat on the other side of the vehicle, so all 6 backing plates are fitted.(ref. diagram27).

Diagram: 27 - RIVET BACKING PLATES TO VEHICLE

CROSS SECTION THRU BACKING PLATE

& SHEETMETAL

CROSS SECTION FOR TEMPORARY

DRILL FIX

1

20mm

SET DRILL STOP TO 20MMDRILL Ø5mm HOLES

SCREW M8 BOLTINTO THE PLATE

APPLY TO 6 PLACES ON TUB FLANGE


SECURE PLATEWITH M8 NUT FROM INSIDE

2

3

ORIENTBACKING PLATE & FITBEHIND SHEETMETAL

FIT(2) RIVETS

Ø5mm

1

2

2

25. Using a Ø12mm redrill the 6 holes in the uteliner only. Remove all burrs and sharp edges from drilled holes. (ref. diagram25).

Diagram: 25 - REDRILL THE HOLES IN UTE LINER REMOVED

1

DRILL OUT THE HOLES IN THE UTE LINER ONLY!

WITH Ø12mm DRILL

3

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FOR VEHICLES NOT FITTED WITH A UTE LINER.0mm 10 20 30 40 50 60 70 80 90

28.Refit the ute liner and attachment hardware to the vehicle. (ref. diagram28).



1

APPLYMASKING TAPE

1

22mm

282mm

742mm

1192mmMASKING

TAPE



Diagram: 29 - MEASURE & MARKING HOLES IN THE SIDE RAILS

29.

FOR VEHICLES NOT FITTED WITH A UTE LINER.

30.

Apply masking tape to the side of the tubside rails as shown and mark line 22mm down from top face. Measure and mark three centre lines starting from the front edge of the tub rail spacer extrusion. First at 282mm, then 742mm and 1192mm. Do the same for the other side ofthe tub side rail. (ref. diagram29).

20mm

Center punch holes position first.Using a Ø3mm drill with a drill stop set to adepth of 20mm, carefully drill out the 3positions on each side (total 6 places),through the sheet metal tub return flange.Redrill each of the 6 holes to Ø9mm with adrill set to a depth of 20mm. (ref. diagram30).

Diagram: 30 - DRILL HOLES IN TUB SIDE RAIL

1

DRILL THE HOLESWITH Ø3mm DRILL AND Ø9mm DRILL

TOP VIEW OF LH CORNER OF TUBSTARTMEASUREFROM FRONTEDGE OF TUBRAIL SPACER

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33.

Diagram: 33 - APPLY ABRASION TAPE TO VEHICLE WITHOUT BEDLINER



2

TAILGATE OFVEHICLE

TOP VIEW OFVEHICLE TUB

CA

BIN

OF

VEH

ICLE

START FROM EDGE OF THE

TAILGATE

FOLD THE TAPE OVERTHE EDGE OFTHE TAILGATE Ensure top of the tub rear corner is clean.

Clean with isopropyl alcohol. Spray rearcorners of top of the tub rails sparingly,using a spray bottle and a mixture of 25%isopropyl alcohol and 75% water (not supplied).On the left hand side of the tub corner,position clear abrasion tape die cut (TAPE0627-LH) and remove backing paper from tape. Fold the tape v-cut sections over the edge of the tub side rail inside. Use squeegee to push out any excesswater solution and bubbles. Wipe awayand dry with clean cloth. When finishedthe tape should be virtually invisible. Repeatwith (TAPE0627RH) on opposite side ofvehicle (ref. diagram33).

1

31.

Screw M8 bolt into the backing plate (CLIP2831PC) and fit into the 9mm hole in the tub.Secure the backing plate with an M8 nut. This is a temporary procedure to ensure the rivet holes are drilled in the correct location.Using a drill with a drill stop set to a depthof 20mm, carefully drill the two (2) markedhole positions to Ø5mm through the backingplate and sheet-metal tub return flange as shown. Remove the backing plate from the tub and uscrew the M8 screw from the backingplate.Remove all burrs and sharp edges fromdrilled holes. Apply rust inhibitor (MISC2776)to all drilled holes.Repeat process for all 3 places on the sameside than repeat on the other side of the vehicle. (ref. diagram31).

Diagram: 31 - DRILL BACKING PLATE RIVET HOLES

32.

Orient and fit the backing plate to theinside of the sheetmetal tub return flangeand secure with two (2) short rivets(FAST0505) as shown.Repeat process for all 3 places on the sameside, than repeat on the other side of the vehicle, so all 6 backing plates are fitted.(ref. diagram32).

Diagram: 32 - RIVET BACKING PLATES TO VEHICLE

CROSS SECTION THRU BACKING PLATE

& SHEETMETAL

CROSS SECTION FOR TEMPORARY

DRILL FIX

1

20mm

SET DRILL STOP TO 20MMDRILL Ø5mm HOLES

SCREW M8 BOLTINTO THE PLATE

SECURE PLATEWITH M8 NUT FROM INSIDE

2

3

ORIENTBACKING PLATE & FITBEHIND SHEETMETAL

FIT(2) RIVETS

Ø5mm

1

2

2

3



RustInhibitor

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34. Using alcohol wipes provided clean alltop rail areas of the tub sheet metal or uteliner and wipe away residue with a dryclean cloth. If heavy cleaning is requireduse Iso-Propyl alcohol and wipe awayresidue with a dry clean cloth.Using priming stick (MISC1365) prime toprails of the tub sheet metal or ute linerwhere foam tape will be applied in(step 34 or 35). Please do not prime toofar over the sides of the top rails or uteliner, read (step 34 or 35) to understandwhere the foam tape is to be positionedand use this as a guide for priming thearea. Follow the instructions on thepriming stick for optimum results.(ref. diagram34).

Diagram: 34 - VEHICLE SURFACE PREPARATION

21

1

23

4

5

6

Apply foam tape (TAPE0386) fromhardware kit to the vehicle tub bed rails andspacer fitted in step 20.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, position15mm 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. diagram35).Tape MUST be fully adhered to tub railsand spacer and sit flat in one continuouslength to prevent water entering thecanopy.

35.

Diagram: 35 - INSTALL WATER SEALING TAPE

APPLYFOAM TAPE

AROUND BED RAIL

TAILGATE OFVEHICLE TOP VIEW OF

VEHICLE TUB

CA

BIN

OF

VEH

ICLE

START AT THEEDGE OF THE

TAILGATE

POSITIONFOAM TAPE

OVER THE EDGE OFTHE INSIDE RADIUS

ALONG THE SIDE RAILS

POSITIONFOAM TAPE

15mm 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

15mm

10mm

10mm


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1

2 3

4

5

6

Apply foam tape (TAPE0386) fromhardware kit to the vehicle ute liner railsand spacer fitted in step 34.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 ute liner railand continue this position all the wayalong the ute liner side rail in onecontinuous length, position 15mmrearward along the front tub spacerextrusion as shown and to the edgeof the inside radius of the top ute 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 ute liner and spacer by applyingmoderate pressure down on the tape all theway around the tub. (ref. diagram36).Tape MUST be fully adhered to ute linerrails and spacer and sit flat in onecontinuous length to prevent waterentering the canopy.

36.


NOT SUPPLIED

37. 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 to the canopy.(ref. diagram37).

Diagram: 37 - APPLY SILICON

APPLYFOAM TAPE

AROUND BED RAIL


VEHICLE TUB

CA

BIN

OF

VEH

ICLE


TAILGATE

POSITIONFOAM TAPE



POSITIONFOAM TAPE



ALONGSIDE RAILS

UTELINER

ALONGSIDE RAILS




ALONGFRONT RAIL

WITH SPACER

15mm

10mm TOSHEET METAL

UTELINER

UTELINER

10mm TOSHEET METAL

FOAMTAPE

FRONT TUBSPACER EXTRUSION

FRONT TUB SPACEREXTRUSION FIRST SLOT


APPLYNON ACETIC SILICON

DETAIL VIEW IFCABIN GUARD

WAS REMOVED


1

2

FOAMTAPE

INTERNAL VIEW INSIDE THE TUB


1


2

UTE LINER FITTEDUTE LINER NOT FITTED


UTELINER

UTELINER

FOR VEHICLES FITTED WITH A UTE LINER.

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NOT SUPPLIED

38. 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.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram38).


APPLY NON ACETICSILICON (NEUTRAL CURE)

FOAMTAPEFRONT TUB

SPACER

VEHICLE CABIN NOTSHOWN FOR CLARITY

1

70mm

39.

IMPOTRTANT!Apply Loctite 243 (not supplied), minimum 20mm along the thread on the M8x30 hex head bolts for each of the 6 bolts.IMPORTANT: Ensure to have the top of thetub mounting bracket set 2mm below toprail of the vehicle tub or tub liner. This is toensure the canopy will seal properly to thetub at the sides.Secure each of the 6 tub mounting bracketswith the black M8x30 bolts, M8 flat washers and M8 spring washers. Tighten all 6 bolts to the torque of 17Nm. (ref. diagram39).

Diagram: 39 - ATTACHING TUB MOUNTING BRACKETS

CROSS SECTION THRU TUB MOUNTING PLATE

& SHEETMETAL

BED LINER NOT SHOWN FOR CLARITY

NOTE: THE TUB MOUNTING PLATEMUST BE SET AT 2mm BELOW

THE TOP OF THE TUB RAIL

NOTE: THE TUB MOUNTING PLATEMUST BE SET AT 2mm BELOWTHE TOP OF THE TUB LINER

M8 FLAT WASHER

(WASH0171-1)

VEHICLETUB SIDE RAIL

M8 SPRING WASHER

(WASH0152-1)

FITTUB MOUNTING

BRACKET (CLIP2890PC)1

TUB LINER

TUB RAIL

2

4

3

M8x30 BOLT(SCRW0846)

CROSS SECTION THRU TUB MOUNTING PLATE,

TUB LINER & SHEETMETAL

FOR VEHICLES FITTED WITH OR WITHOUT A UTE LINER.20mm

LOCTITE24313mm 17Nm

13mm

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CLEANCANOPY FRONT

1

DO NOT SLIDE CANOPYON FOAM TAPEAND SILICON

2 FITCANOPY TO

VEHICLE

1 TAPEWIRING HARNESS

TO RH SIDE WINDOW

42. Align the canopy evenly on the tub.From inside the canopy ensure the slottedholes in the front rail of the canopy align sideways to the slotted holes in the front tubspacer extrusion (ALUM0038-7).Loosely drop two (2) M6x25 bolts (SCRW0868) into the outer most slots to alignthe canopy sideways at the front.Open rear door to check sidewaysalignment at the rear. (ref. diagram42).

40.

41.

Clean front of canopy including the frontwindow and vehicle’s rear cabin window.(ref. diagram40).

Four people are required to lift thecanopy.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 foam tape and silicon, as this candamage the foam tape and spread thesilicon (break the water seal).(ref. diagram41).

Diagram: 42 - ALIGN CANOPY TO TUB

Diagram: 41 - FIT CANOPY TO TUB

Diagram: 40 - PREPARE CANOPY- CLEAN VEHICELS CAB & CANOPY FRONT

ALIGN SLOTS AND FIT 2 BOLTSTO OUTER MOST SLOTS

TOP VIEW INSIDE CANOPY AT FRONT RAIL

1

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The canopy lower perimeter aluminiumbase rail front face, should align with the frontof the tub spacer extrusion (ALUM0038-7) using a straight edge as shown. (ref. diagram44).

45.The slots in the canopy base rails should nowalign to the holes in the top face of each ofthe tub mounting brackets. IMPORTANT: Apply Loctite 243 (not supplied) minimum 20mm along the threadof the bolts.Only assemble bolts the rear most tub mounting brackets and canopy base railstowards the tailgate and of the vehicle.Torque to 8Nm. (ref. diagram45).

Diagram: 45 - ATTACH CANOPY TO THE TUB AT REAR FIRST


TUB SPACER

M6 NUT(NUTS0161)

M6 FLAT WASHER

(WASH0169)

M6 FLAT WASHER

(WASH0169)

M6 SPRING WASHER

(WASH0103)

8Nm

10mm

43. Open rear tailgate to check sidewaysalighment of the canopy to the tub, measurewith a ruler from the vehicle’s side tub railedge to the flange on the canopy base rail. Make this even both sides. Check towardsthe front, middle and rear end of the canopy.(ref. diagram43).

Diagram: 43 - ALIGN CANOPY TO TUB SIDEWAYS

EVEN BOTH SIDES

REAR SECTION VIEW

A=BA B

44.


ALIGN FRONT OF CANOPYBASE EDGE EXTRUSION TO

FRONT OF TUB SPACER(ALUM0038-7)

0mm

1020

3040

5060

7080

90

TUB SPACER

2

20mm

LOCTITE243


FRONT OF TUB SPACER

0mm

1020

3040

5060

7080

90

1

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47. Once you are happy with the position of thecanopy on the vehicle, before bolting thecanopy to the four remaining brackets,IMPORTANT: Apply Loctite 243 (not supp-lied), minimum 20mm along the thread ofeach bolt. Then assemble the canopy through the base rails to the attachmentbrackets, per each bracket, with two M6x25 (SCRW0868) bolts, four flat washes (WASH0169), two spring washers (WASH0103) and two nuts (NUTS0161) as shown.Torque order to follow: IMPORTANT: all bolts to be done up to Torque 9Nm. Do rear tailgate brackets first, front brackets second and middle brackets third. (ref. diagram47).

Diagram: 47 - BOLT CANOPY TO SIDE RAILS


8Nm

10mm

20mm

LOCTITE243

CLOSE REAR DOOR &RE-CHECK EASE OF TURNING

LOCKS TO LOCK

4

3

3

2

2

2

TORQUE BRACKETS BOLTS TO 8Nm


ADJUSTCANOPY FORWARD

IF SEAL IS NOT SEALINGON LOWER DOOR

EDGE TO TUB

ADJUSTIF LOCKS ON REAR

DOOR ARE TOOHARD TO TURN

10mm

9Nm

10mm

10mm

If you need to adjust the position of the canopy,to ensure the rear door sash seals to the tailgate,loosen the bolts on the clamps fittedpreviously in (step 43).Adjust the canopy position slightly forward onthe vehicle if the seal is not sealing, or slightlyrearward on the vehicle if the locks are too hardto turn and close.Re-tighten the bolts to Torque 8Nm.Close rear door and re-check locking. (ref. diagram46).

46.

Diagram: 46 - CHECK AND ADJUST REAR DOOR SEALING & LOCKS

1

1

1

LOOSENBRACKETS BOLTS

CROSS SECTION’S THRU SIDE RAIL BRACKET MOUNTING POSITION

VEHICLES WITH-OUTUTE LINER FITTED

VEHICLES WITHUTE LINER FITTED

M6x25HEX HEAD

BOLT

UTE LINER

MOUNTINGBRACKET

MOUNTINGBRACKET

M6x25HEX HEAD

BOLT

M6 x19mmODWASHERS

M6 SPRINGWASHERS

M6 NUTS

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10mm

TIGHTEN TOTORQUE 9Nm

1 FITBOLT AND WASHER

SECURENUT WITH FLAT WASHER

AND SPRING WASHER

2

9Nm

10mm 48. Bolt the front rail of the canopy to the underside of the canopy front tub spacer extrusion (ALUM0038-7). IMPORTANT: Apply Loctite 243 (not supp-lied), minimum 20mm along the thread ofeach bolt. Secure with four (4) M6x25 hex head bolts,eight (8) M6 flat washers and four M6 spring washers and nuts as shown. Tighten to Torque 9Nm. (ref. diagram48).

Diagram: 48 - BOLT FRONT OF CANOPY TO TUB SPACER RAIL

FLAT WASHER

M6 NUT

M6 BOLT

SPRING WASHER

FRONT TUBSPACER

CANOPY BASERAIL AT FRONT

VEHICLEFRONT TUB

SHEET METAL

CANOPY BASERAIL

25mm

BEDLINER

SECTION THROUGH FRONT END OF CANOPYTOWARDS VEHICLE FRONT

VEHICLEFRONT TUB

SHEET METAL

20mm

LOCTITE243

MARK DOWN 25mm FROM UNDERSIDE OF CANOPYFRONT TUB SPACER RAIL

CENTERLINE OFVEHICLE

Ø5mm

(x4)

1

1

2

349. Mark and drill four (4) Ø5mm holes into

the bedliner vehicle tub front panel usingdimension’s as shown.Rivets must secure to flat form on tub.Apply rust inhibitor to all drilled holes inthe tub sheet metal.Secure with four (4) long stainless steelrivets (FAST0613) as shown.(ref. diagram49).

Diagram: 49 - SECURE FRONT OF BEDLINER

135135 270270

TAILGATE

REARDOOR SASH

MASKINGTAPE

REAR WINDOW

APPLYMASKING TAPETO TAILGATE

150. With the canopy rear door closed, apply

a length of masking tape to the reartailgate, level with the bottom edge ofthe canopy rear door sash, when viewedfrom the rear horizontal position as shown.This will assist in positioning the clearabrasion tape applied to the top of thetailgate in the next step. (ref. diagram50).

Diagram: 50- APPLY MASKING TAPE


FOR VEHICLES WITHOUT A UTE LINER FITTED.

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CLEARABRASION

TAPE TRIMEXCESS CLEARABRASION TAPE

3

REMOVEMASKING TAPE

CANOPY NOT SHOWN FOR CLARITY

5

SQUEEGEE OUTEXCESS SOLUTION

BUBBLES

41

1

25% ISOPROPYLALCOHOL

75% WATER

APPLYCLEAR

ABRASION TAPE

REMOVE LHS TAILLIGHT

TAILLIGHT

SCREW

ALIGNBOTTOM EDGE

OF CLEAR ABRASIONTAPE WITH TOP EDGE

OF MASKING TAPE

2

51. Using a solution of 25% isopropyl alcoholand 75% water in a spray bottle (not -supplied), thoroughly spray along the topof the tailgate. Remove liner from clearabrasion tape. Working from one end witha 5mm overhang to the side of the tailgate,place clear abrasion tape (TAPE0611-1) onthe tailgate. Trim excess tape leaving a 5mmoverhang at both ends of the tailgate. Whenin position, use a squeegee to push out anyexcess water solution and bubbles. Using scissors, trim tape to end of tailgate.You may need to squeegee a few times.When finished the tape is virtuallyinvisible. To ensure a good finish please take carean do not rush this step. Remove maskingtape. (ref. diagram51).

Diagram: 51 - APPLY ABRASION TAPE

2

52. Open the tailgate and unscrew the two (2) screews holding the taillight.Pull the taillight out and let it hang out onthe wiring harness. (ref. diagram52)

Diagram: 52 - REMOVE REAR LHS TAILIGHT

3

1

WIRING LOOM

WIRING LOOM

CORRUGATED TUBE

HOLE IN THE TUBSHEETMETAL

TAILGATE

PUSHGROMMET

INTOSHEETMETAL

2

53. The wiring for the canopy light is attached tothe inside left hand corner of the canopy. Open the rear door and tailgate. First slide the 100mm corrugated tube from (LOOM0050) kit onto the wiring after the grommet, then slide the grommet up to the wiring loom using soapy water. Feed the wiring into the hole in the rear LH side tub sheetmetal. Take care not to damage the wiring loom.Slide the grommet along the loom and fitit to the hole in the sheetmetal. (ref. diagram53).

Diagram: 53 - FIT WIRING INTO THE TUB SHEETMETAL

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7

Diagram: 55 - RUN HARNESS ALONG CHASSIS RAIL

55. IMPORTANT: Take care under thevehicle as the exhaust may be hot.Continue the harness along the chassis rail with existing wiring, up to the front left hand wheel arch as shown. Fit cable ties in sequence listed.Trim excess cable tie length with side cutters.Ensure harness is run in a direct route fromthe rear of the vehicle to the front.IMPORTANT: Keep harness position awayfrom any brake lines or exhaust system.(ref. diagram55).

3 CHASSIS RAIL

SEE STEP 56 SEE STEP 57 SEE STEP 59 SEE STEP 58

12

56. Pull the wiring under the chassis from thetail light and secure to the existing wiringwith a short cable tie.(ref. diagram56).

Diagram: 56 - FIT WIRING INTO THE TUB REAR TAIL LIGHT

1

WIRING LOOM

CABLE TIE


WIRINGLOOM

54. Continue threading the wiring into the holeat the bottom of the taillight cavity.Secure the wiring with a short cable tie toa hole at the edge of the sheetmetal.(ref. diagram54).

Diagram: 54 - ATTACH WIRING INTO THE LHS REAR TAILLIGHT

200mm CABLE TIE

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58. Feed the canopy harness along thechassis rail as shown.Fit three (3) cable ties along the chassisrail as shown. Trim excess cable tie lengthwith side cutters. IMPORTANT: Wiring harnesses shouldbe positioned away from the exhaustsystem side. Place it on the top outboardside of the chassis rail. (ref. diagram58).

59. Using a draw wire down through the enginebay, attach it to the loose end of the loomand pull up through the engine bay.(ref. diagram59).

Diagram: 58 - ATTACHING WIRING ALONG THE CHASSIES RAIL

Diagram: 59 - DRAWING THE WIRING INTO THE ENGINE BAY

CHASSISRAIL

VIEW LOOKING FROM MIDDLE OF THE VEHICLE TO LH OUTSIDE

FRONT OFVEHICLE

600mm CABLE TIES

57. Feed the wiring loom along the chassisrail above the rear wheel and tuck the loombehind the brackets as shown. Secure witha short cable tie to the existing vehicle’swiring harness. (ref. diagram57).

Diagram: 57 - ROUTING WIRING LOOM AT THE REAR WHEEL

FRONT OFVEHICLE

FRONT OFVEHICLE

600mm CABLE TIE

200mm CABLE TIE

TYRE

CHASSIESRAIL

CHASSIESRAIL

WIRING LOOM

WIRING LOOM

WIRING LOOM

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1

60. Once the wiring is pulled inside the enginebay, use the short cable ties in 3 spots tosecure the wiring to the existing harness.Follow the fire wall to the left side and along the fender towards the battery, as shown. (ref. diagram60).

61. Strip 5mm of the wire insulation on each wireand apply internal diameter ring terminals to ends of each wire.NOTE: The red terminal onto the red wireand black termminal onto the black wire.Crimp terminals to wires solidly.(ref. diagram61).

62. Measure and mark 100mm on the red wireand cut with sidecutters.NOTE: Only cut the red terminal.(ref. diagram62).

Diagram: 60 - ROUTING THE WIRE UNDER THE HOOD

Diagram: 61 - APPLY RING TERMINALS

Diagram: 62 - CUT THE RED WIRE AT 100mm

2 200mm CABLE TIE

BATTERY

WIRING LOOM

RED WIRE

8MM RINGTERMINALS

CUT AT 100mm

DRAW WIRINGINTO THE ENGINE

BAY

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100mm

REST OF RED LOOM

63. Insert both red wires into the Blade Fuse holder, as shown. Close the fuse holder firmly till it clicks together.(ref. diagram63).

64. Slide the 5Amp Blade Fuse into the BladeFuse holder, as shown.(ref. diagram64).

65.

Diagram: 63 - LOCK RED WIRE INTO BLADE FUSE HOLDER

Diagram: 64 - SLIDE FUSE INTO THE HOLDER

Diagram: 65 - CONNECT LOOM TO BATTERY TERMINALS

Position harness and cables as shown.Fit black cable eyelet terminal to the threadon the batteries negative “-” terminal andsecure with (1) M6 ZP hex nut.Lift up the red cap on the batteries positive“+” terminal and fit the red cable eyeletterminal to the thread with (1) M6 ZP hexnut.Refit red cap so it neatly sits over the positiveterminal.(ref. diagram65).

FIT BLACK CABLE TERMINAL& M6 ZP HEX NUT TO

BATTERY NEGATIVE TERMINAL

FIT RED CABLE TERMINAL& M6 ZP HEX NUT TO

BATTERY POSITIVE TERMINAL

1 2

--

RED WIRE

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CANOPYLAMP

PLACE FITTING INSTRUCTIONSIN THE CUSTOMERS LOG BOOK

Diagram: 67 - FINAL CLEANING

Clean canopy including all windowsand vehicle thoroughly .Place fitting instructions in theCustomers log book, and ensurepage 49 of these instructions arediscussed with the customer and acopy is given to the customer. (ref. diagram67).

67.

Open the rear door and check that theinternal canopy lamp is operating correctlywhen switched to the ’ON’ position. (ref. diagram66).

Diagram: 66 - CHECK CANOPY LIGHT

OPENREAR DOOR

66.

CHECKCANOPY LAMP

WORKS

CONTINUE ON THE NEXT PAGE FOR J-DECK CANOPYINSTALLATION INSTRUCTIONS

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IF A SPORTS BAR IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 68.IF A CABIN GUARD IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 69.

IF THE VEHICLE HAS NO CABIN GUARD OR SPORTS BAR PLEASE PROCEED TO STEP 80.

Using cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the canopy, and a piece betweenthe tub and cabin as a protection sheetwhile removing the cabin guard.(ref. diagram69).

69.


Apply 200mm lengths of overlappingmasking tape to the top and side of thetub rail, up to and around the cabin guardas shown.Recommended: Fit a 2mm thick steelplate as a sacrificial grinding plate (Notsupplied in kit), next to the cabin guardas shown, repeat process for the otherside of the vehicle. (ref. diagram70).

70.


FITTAPE

RECOMMENDEDFIT SACRIFICIALGRINDING PLATE

1

2

POSITIONCARDBOARD

TUB AND CABINPROTECTION MATS

CABIN GUARD

REAR TUBE

SHAKE PROOFWASHER

MOUNTING FOOTWASHER

NUT PLATE

FRONTNUT PLATE REAR

NUT PLATE

BOLTUTE BODY

REMOVEHARDWARE

Remove the six (6) bolts and four (4) nutplates holding the sports bar feet to the tub as shown.Carefully remove the sports bar from thevehicle and return to the customer withall hardware components.(ref. diagram68).

68

Diagram: 68 - REMOVE SPORTS BAR & HARDWARE

2

1

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Secure the sacrificial grinding plate (notsupplied in kit) to the tub rail by coveringit with masking tape as shown.Repeat process for the other side of thevehicle. (ref. diagram71).

71.

Insert a suitable protective timber boardof adequate thickness between thecardboard and cabin guard as shown.IMPORTANT: To avoid accidentaldamage to the vehicle, the timber boardMUST be used when ever cutting of thecabin guard is undertaken.(ref. diagram72).

IMPORTANT: Ensure that the vehicle’s(paint work, glass, etc...) is adequatelyprotected before removing the cabinguard.Using a medium sized angle grinder,partially cut through the rear and sidefaces of the LH outer cabin guard bar,taking care not to damage vehiclesurfaces.Repeat process for the RH side of thevehicle, ensuring the protective timberboard is repositioned behind the RH outercabin guard bar. (ref. diagram73).

72.


73.



PARTIALLY CUT THROUGHOUTER CABIN GUARD BARS

SECURESACRIFICIAL GRINDING

PLATE WITH TAPE

INSERTTIMBER BOARD

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IMPORTANT: Ensure the protectivetimber board is repositioned behind each of the centre support bars beforecutting.Using a medium sized angle grinder,completely cut through the three (3)centre support bars at the base, flush tothe front tub rail, taking care not todamage vehicle surfaces. (ref. diagram74).

74.

IMPORTANT: Ensure the protectivetimber board is repositioned behind the outer cabin guard bars beforecutting.Two people are required to completethis step, one person will need tosupport the cabin guard and prevent itfrom damaging the vehicle while theother person finishes cutting throughthe cabin guard bars completely.Using a medium sized angle grinder,completely cut through the LH and RHouter cabin guard bars, flush to thegrinding plates.Carefully remove cabin guard fromvehicle and discard. (ref. diagram75).

IMPORTANT: Ensure the protectivetimber board is repositioned to each bar location before cutting.Take care to prevent damage to vehicle.Using a medium sized angle grinder,carefully cut away any remaining metalnot flush with the tub rail.Remove sacrificial grinding plates andall masking tape. (ref. diagram76).

75.


76.



1

2

INSERTTIMBER BOARD

COMPLETELY CUT THROUGHCENTRE SUPPORT BARS

1

2

SUPPORTCABIN GUARD

COMPLETELY CUT THROUGHOUTER CABIN GUARD BARS

1

2

GRINDAWAY ANY REMAINING

METAL NOT FLUSHWITH THE TUB

REMOVEGRINDING PLATES

& TAPE

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Using a file / de-burring tool, remove allburrs and sharp edges from cabin guardand tub rail surfaces previously cut withthe angle grinder. (ref. diagram10).

77.

Remove all timber boards and cardboardprotection mats from the vehicle.Retain cardboard tub floor protection matfor use later during the fitment.Using compressed air, completely blowout all metal filings, swarf etc... in the tubfloor. (ref. diagram78).

Using a suitable metal primer, paint overand completely cover all bare metalsurfaces previously cut and deburred.(ref. diagram79).

78.

Diagram: 78 - CLEAN VEHICLE SURFACES

79.

Diagram: 79 - PRIME VEHICLE SURFACES


1 REMOVETIMBER BOARDS& CARDBOARD

PROTECTION MATS

DEBURRALL SURFACES AROUNDCUT CABIN GUARD BARS

2

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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. diagram80).

80.

Diagram: 80 - CLEAN & DRY INSTALLATION AREAS

POSITIONCARDBOARD TUBPROTECTION MAT

1

2

81. Apply masking tape across the front of theute liner as per highlighted surfacesacross the front of the ute liner mark a line8mm down from the top face.Measure and mark a line at the centre ofthe ute liner and then 760mm outboardeach side of the centreline as shown.Apply masking tape in the rear LH side topcorner of the ute liner, mark two lines, onevertical at 90mm from the edge of the liner and one at 35mm up from the horizontalstep in the liner. (ref. diagram81).

Diagram: 81 - MEASURE & MARK UTE LINER

82. Remove and retain the ute liner andattachment hardware from the vehicle.(ref. diagram82).


REMOVE & RETAINUTE LINER & ALL HARDWARE

PROCEED FOR VEHICLES WITH A UTE LINER FITTED.

IF VEHICLE IS FITTED WITH A UTE LINER, PLEASE PROCEED WITH STEPS 81IF VEHICLE IS NOT FITTED WITH A UTE LINER, PLEASE PROCEED TO STEP 84

APPLYMASKING TAPE

0mm 10 20 30 40 50 60 70 80 90

8mm

MEASURE & MARKA LINE ACROSS THE LINER


2

MEASURE & MARKCENTRELINE OF UTE LINER

1

4

3

760mm TOCENTRE OFUTE LINER

CROSS SECTIONTHROUGH FRONT

OF UTE LINER

8mm

1


90mm35mm

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30Ømm

83. Using a jigsaw or similar, carefully cut thefront top section of the ute liner off usingthe lines marked 8mm down from the top.Remove all burrs and sharp edges with afile or deburring tool or angle grinder withdisc sanding attachment. Using a 3mm drill put a pilot hole in the rearLH side of the liner where the hole centehas been marked. Redrill with a 30mm holesaw. When complete remove all masking tape from the ute liner. (ref. diagram83).

Diagram: 83 - CUT UTE LINER FRONT PART AWAY & DRILL REAR HOLE

DRILL OUT THE Ø3MMPILOT HOLE IN THE

UTE LINER TO Ø30MM USING HOLE SAW

CUT OUT and DEBURRTHE FRONT MARKED

AREA CAREFULLY

1

84. Apply masking tape to the back rear cornerof the tub, mark out position of hole.100mm from top of the tub rail and 45mmfrom inside edge of the tailgate opening.Pilot drill hole Ø3mm and drill out to Ø9mmhole. Apply rust inhibitor to the hole.(ref. diagram84).

Diagram: 84 - DRILL WIRING HOLE IN REAR LH SIDE TUB 85. Refit the ute liner and attachment hardware

to the vehicle. (ref. diagram85).



1

2

1

45mm

100mm

RustInhibitor


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NOT SUPPLIED

FRONT TUB SPACER EXTRUSION

85. 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 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. diagram85).

Diagram: 85 - FIT 3M DOUBLE SIDED TAPE 12x1700mm

86.

87.

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. diagram86).

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 rearwardand down on the front tub spacer extrusionalong the length to ensure maximumadhesion of the foam tape. Clean anyexcess silicon off using isopropyl alcohol.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. diagram87).

Diagram: 87 - FIT RAIL EXTRUSION TUB SPACER

Diagram: 86 - APPLY SILICON TO THE TUB SPACER

FRONT RAIL

FRONT OF THE VEHICLE

TOP VIEW OF TUB

TAPE COVERSHALF OF THE HOLE

APPLYDOUBLE SIDED 12x1700mm ROLL(TAPE0615) ACROSS FRONT RAIL

1

4

POSITION DOUBLE SIDED TAPE AGAINST 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

APPLY12mm BEAD OF SILICON

TUBSPACER(ALUM0038-7)

TAPE

FRONT OF CAR

VIEW FROM TOP OF VEHICLE

CROSS SECTIONTHROUGH FRONT RAIL

SILICONFRONT RAILOF TUBUTE LINER(IF FITTED)

2

3

5 1 2 MEASURE & MARKCENTRE LINE OF TUB SPACER

MEASURE & MARKCENTRE LINE OF FRONT RAIL

= =3

4

1222.5

SILICON

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88. Apply masking tape to the side of the uteliner as shown and mark line 22mm downfrom top face. Measure and mark three centre lines starting from the front edge of the tub rail spacer extrusion just fitted.First at 282mm, then 742mm and 1192mm. Do the same for the other side of the uteliner. (ref. diagram88).


0mm 10 20 30 40 50 60 70 80 90

0mm 10 20 30 40 50 60 70 80 90

APPLYMASKING TAPE

1

20mm

Diagram: 88 - MEASURE & MARK UTE LINER SIDE HOLES ON VEHICLE

22mm

282mm

742mm

1192mm

APPLYMASKING

TAPE

1



22mm

282mm

742mm

1192mmMASKING

TAPE



89. Using a Ø3mm drill with a drill stop set to adepth of 20mm, carefully drill out the 3positions on each side (total 6 places),through the bed liner and through the sheetmetal tub return flange.Redrill each of the 6 holes to Ø9mm with adrill set to a depth of 20mm. Apply rust inhibitor to the holes from theoutside of the tub side rails.(ref. diagram89).

Diagram: 89 - DRILL HOLES IN THE UTE LINER ON VEHICLE

1DRILL THE HOLES

WITH Ø3mm DRILL AND Ø9mm DRILL


TOP VIEW OF LH CORNER OF TUB


Diagram: 90 - MEASURE & MARKING HOLES IN THE SIDE RAILS

90.

Apply masking tape to the side of the tubside rails as shown and mark line 22mm down from top face. Measure and mark three centre lines starting from the front edge of the tub rail spacer extrusion. First at 282mm, then 742mm and 1192mm. Do the same for the other side ofthe tub side rail. (ref. diagram90).

STARTMEASUREFROM FRONTEDGE OF TUBRAIL SPACER

TOP VIEW OF LH CORNER OF TUBSTARTMEASUREFROM FRONTEDGE OF TUBRAIL SPACER

RustInhibitor

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92.

Diagram: 92 - APPLY ABRASION TAPE TO VEHICLE WITHOUT BEDLINER

93. Using alcohol wipes provided clean alltop rail areas of the tub sheet metal or uteliner and wipe away residue with a dryclean cloth. If heavy cleaning is requireduse Iso-Propyl alcohol and wipe awayresidue with a dry clean cloth.Using priming stick (MISC1365) prime toprails of the tub sheet metal or ute linerwhere foam tape will be applied in(step 94 or 95). Please do not prime toofar over the sides of the top rails or uteliner, read (step 94 or 95) to understandwhere the foam tape is to be positionedand use this as a guide for priming thearea. Follow the instructions on thepriming stick for optimum results.(ref. diagram93).

Diagram: 93 - VEHICLE SURFACE PREPARATION

21

2

TAILGATE OFVEHICLE

TOP VIEW OFVEHICLE TUB

CA

BIN

OF

VEH

ICLE

START FROM EDGE OF THE

TAILGATE

FOLD THE TAPE OVERTHE EDGE OFTHE TAILGATE Ensure top of the tub rear corner is clean.

Clean with isopropyl alcohol. Spray rearcorners of top of the tub rails sparingly,using a spray bottle and a mixture of 25%isopropyl alcohol and 75% water (not supplied).On the left hand side of the tub corner,position clear abrasion tape die cut (TAPE0627-LH) and remove backing paper from tape. Fold the tape v-cut sections over the edge of the tub side rail inside. Use squeegee to push out any excesswater solution and bubbles. Wipe awayand dry with clean cloth. When finishedthe tape should be virtually invisible. Repeatwith (TAPE0627RH) on opposite side ofvehicle (ref. diagram92).

1



91.

20mm

Center punch holes position first.Using a Ø3mm drill with a drill stop set to adepth of 20mm, carefully drill out the 3positions on each side (total 6 places),through the sheet metal tub return flange.Redrill each of the 6 holes to Ø9mm with adrill set to a depth of 20mm. Apply rust inhibitor to the holes.(ref. diagram91).

Diagram: 91 - DRILL HOLES IN TUB SIDE RAIL

1DRILL THE HOLES

WITH Ø3mm DRILL AND Ø9mm DRILL

RustInhibitor

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1

23

4

5

6

Apply foam tape (TAPE0386) fromhardware kit to the vehicle tub bed rails andspacer fitted in step 20.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, position15mm 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. diagram94).Tape MUST be fully adhered to tub railsand spacer and sit flat in one continuouslength to prevent water entering thecanopy.

94.


CONTINUE ON NEXT PAGE

APPLYFOAM TAPE

AROUND BED RAIL


VEHICLE TUBC

AB

IN O

F VE

HIC

LE


TAILGATE

POSITIONFOAM TAPE



POSITIONFOAM TAPE



ALONGSIDE RAILS

ALONGSIDE RAILS




ALONGFRONT RAIL

WITH SPACER

15mm

10mm

10mm


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1

2 3

4

5

6

Apply foam tape (TAPE0386) fromhardware kit to the vehicle ute liner railsand spacer fitted in step 87.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 ute liner railand continue this position all the wayalong the ute liner side rail in onecontinuous length, position 15mmrearward along the front tub spacerextrusion as shown and to the edgeof the inside radius of the top ute 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 ute liner and spacer by applyingmoderate pressure down on the tape all theway around the tub. (ref. diagram95).Tape MUST be fully adhered to ute linerrails and spacer and sit flat in onecontinuous length to prevent waterentering the canopy.

95.


NOT SUPPLIED

96. 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 to the canopy.(ref. diagram96).


APPLYFOAM TAPE

AROUND BED RAIL


VEHICLE TUB

CA

BIN

OF

VEH

ICLE


TAILGATE

POSITIONFOAM TAPE



POSITIONFOAM TAPE



ALONGSIDE RAILS

UTELINER

ALONGSIDE RAILS




ALONGFRONT RAIL

WITH SPACER

15mm

10mm TOSHEET METAL

UTELINER

UTELINER

10mm TOSHEET METAL

FOAMTAPE





DETAIL VIEW IFCABIN GUARD

WAS REMOVED


1

2

FOAMTAPE

INTERNAL VIEW INSIDE THE TUB


1


2

UTE LINER FITTEDUTE LINER NOT FITTED


UTELINER

UTELINER


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M8x25mmALLEN KEY

SCREW

M8x25mmALLEN KEY

SCREW

MOUNTINGBRACKET

MOUNTINGBRACKETCANOPY

SIDE RAIL

CANOPYSIDE RAIL

CANOPYBEDLINER

M8 FLATWASHERS

M8 FLATWASHERS

M8 NYLOCM8 NYLOC

M8 NYLOCNUT(NUTS0242)

NOT SUPPLIED

97. 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.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram97).


APPLY NON ACETICSILICON (NEUTRAL CURE)

FOAMTAPEFRONT TUB

SPACER

VEHICLE CABIN NOTSHOWN FOR CLARITY

1

70mm

98.

IMPOTRTANT!Apply Loctite 243 (not supplied), minimum 20mm along the thread on the M8x25 allen head screw for each of the 6 screws.IMPORTANT: Ensure to have the top of thetub mounting bracket set 2mm below toprail of the vehicle tub or tub liner. This is toensure the canopy will seal properly to thetub at the sides.Secure each of the 6 tub mounting bracketswith the M8x25 allen head screws, M8 flat washers and M8 nylock nuts. Tighten all 6 screws to torque of 17Nm. NOTE: Use only a ball ended allen key inbolt heads, for access to screw in allen head screws). (ref. diagram98)

Diagram: 98 - ATTACHING TUB MOUNTING BRACKETS

CROSS SECTION THRU TUB MOUNTING PLATE

& SHEETMETAL

BED LINER NOT SHOWN FOR CLARITY

NOTE: THE TUB MOUNTING PLATEMUST BE SET AT 2mm BELOW

THE TOP OF THE TUB RAIL

NOTE: THE TUB MOUNTING PLATEMUST BE SET AT 2mm BELOWTHE TOP OF THE TUB LINER

CROSS SECTION THRU TUB MOUNTING PLATE,

TUB LINER & SHEETMETAL


20mm

LOCTITE24317Nm

13mm

BallEnded

M8 FLAT WASHER

(WASH0171)

VEHICLETUB SIDE RAIL

FITTUB MOUNTING

BRACKET (CLIP2890PC)1

2

4

M8x25mm ALLENKEY SCREW(SCRW0623)

TORQUE TO 17Nm

M8 FLATWASHERS

(WASH0171)

3

2

VIEW FROM OUTSIDEOF THE VEHICLE

VIEW FROM INSIDE OF THE VEHICLE

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CLEANCANOPY FRONT

1

DO NOT SLIDE CANOPYON FOAM TAPEAND SILICON

2 FITCANOPY TO

VEHICLE

1 TAPEWIRING HARNESS

TO RH SIDE WINDOW

101. Align the canopy evenly on the tub.From inside the canopy ensure the slottedholes in the front rail of the canopy align sideways to the slotted holes in the front tubspacer extrusion (ALUM0038-7).Loosely drop two (2) M6x25 bolts (SCRW0868) into the outer most slots to align the canopy sideways at the front.Open rear door to check sidewaysalignment at the rear. (ref. diagram101).

99.

100.

Clean front of canopy including the frontwindow and vehicle’s rear cabin window.(ref. diagram99).

Four people are required to lift thecanopy.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 foam tape and silicon, as this candamage the foam tape and spread thesilicon (break the water seal).(ref. diagram100).


Diagram: 100 - FIT CANOPY TO TUB

Diagram: 99 - PREPARE CANOPY- CLEAN VEHICELS CAB & CANOPY FRONT

ALIGN SLOTS AND FIT 2 BOLTSTO OUTER MOST SLOTS

TOP VIEW INSIDE CANOPY AT FRONT RAIL

1

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20mm

LOCTITE243

The canopy lower perimeter aluminiumbase rail front face, should align with the frontof the tub spacer extrusion (ALUM0038-7) using a straight edge as shown. (ref. diagram103).

104.The slots in the canopy base rails should nowalign to the holes in the top face of each ofthe tub mounting brackets. IMPORTANT: Apply Loctite 243 (not supplied) minimum 20mm along the threadof the bolts.Only assemble bolts the rear most tub mounting brackets and canopy base railstowards the tailgate and of the vehicle.Torque to 8Nm. (ref. diagram104).

Diagram: 104 - ATTACH CANOPY TO THE TUB AT REAR FIRST


TUB SPACER

M6 NUT(NUTS0161)

M6 FLAT WASHER

(WASH0169)

M6 FLAT WASHER

(WASH0169)

M6 SPRING WASHER

(WASH0103)

8Nm

10mm

102. Open rear tailgate to check sidewaysalighment of the canopy to the tub, measurewith a ruler from the vehicle’s side tub railedge to the flange on the canopy base rail. Make this even both sides. Check towardsthe front, middle and rear end of the canopy.(ref. diagram102).

Diagram: 102 - ALIGN CANOPY TO TUB SIDEWAYS

EVEN BOTH SIDES

REAR SECTION VIEW

A=BA B

103.



FRONT OF TUB SPACER(ALUM0038-7)

0mm

1020

3040

5060

7080

90

TUB SPACER

2ALIGN FRONT OF CANOPY

BASE EDGE EXTRUSION TOFRONT OF TUB SPACER

0mm

1020

3040

5060

7080

90

1

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20mm

LOCTITE243

106.Once you are happy with the position of thecanopy on the vehicle, before bolting thecanopy to the four remaining brackets,IMPORTANT: Apply Loctite 243 (not supp-lied), minimum 20mm along the thread ofeach bolt. Then assemble the canopy through the base rails to the attachmentbrackets, per each bracket, with two M6x25 (SCRW0868) bolts, four flat washes (WASH0169), two spring washers (WASH0103) and two nuts (NUTS0161) as shown.Torque order to follow: IMPORTANT: all bolts to be done up to Torque 9Nm. Do rear tailgate brackets first, front brackets second and middle brackets third. (ref. diagram106).

Diagram: 106 - BOLT CANOPY TO SIDE RAILS


8Nm

10mm

CLOSE REAR DOOR &RE-CHECK EASE OF TURNING

LOCKS TO LOCK

4

3

3

2

2

2



ADJUSTCANOPY FORWARD

IF SEAL IS NOT SEALINGON LOWER DOOR

EDGE TO TUB

ADJUSTIF LOCKS ON REAR

DOOR ARE TOOHARD TO TURN

10mm

9Nm

10mm

10mm

If you need to adjust the position of the canopy,to ensure the rear door sash seals to the tailgate,loosen the bolts on the clamps fittedpreviously in (step 43).Adjust the canopy position slightly forward onthe vehicle if the seal is not sealing, or slightlyrearward on the vehicle if the locks are too hardto turn and close.Re-tighten the bolts to Torque 8Nm.Close rear door and re-check locking. (ref. diagram105).

105.

Diagram: 105 - CHECK AND ADJUST REAR DOOR SEALING & LOCKS

1

1

1

LOOSENBRACKETS BOLTS

CROSS SECTION’S THRU SIDE RAIL BRACKET MOUNTING POSITION

VEHICLES WITH-OUTUTE LINER FITTED

VEHICLES WITHUTE LINER FITTED

M6x25HEX HEAD

BOLT

UTE LINER

MOUNTINGBRACKET

MOUNTINGBRACKET

M6x25HEX HEAD

BOLT

M6 x19mmODWASHERS

M6 SPRINGWASHERS

M6 NUTS

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20mm

LOCTITE243

10mm

TIGHTEN TOTORQUE 9Nm

1 FITBOLT AND WASHER

SECURENUT WITH FLAT WASHER

AND SPRING WASHER

2

9Nm

10mm 107. Bolt the front rail of the canopy to the underside of the canopy front tub spacer extrusion (ALUM0038-7). IMPORTANT: Apply Loctite 243 (not supp-lied), minimum 20mm along the thread ofeach bolt. Secure with four (4) M6x25 hex head bolts,eight (8) M6 flat washers and four M6 spring washers and nuts as shown. Tighten to Torque 9Nm. (ref. diagram107).

Diagram: 107 - BOLT FRONT OF CANOPY TO TUB SPACER RAIL

CONTINUE ON NEXT PAGE

FLAT WASHER

M6 NUT

M6 BOLT

SPRING WASHER

FRONT TUBSPACER

CANOPY BASERAIL AT FRONT

VEHICLEFRONT TUB

SHEET METAL

CANOPY BASERAIL

25mm

BEDLINER

SECTION THROUGH FRONT END OF CANOPYTOWARDS VEHICLE FRONT

VEHICLEFRONT TUB

SHEET METAL

MARK DOWN 25mm FROM UNDERSIDE OF CANOPYFRONT TUB SPACER RAIL

CENTERLINE OFVEHICLE

Ø5mm

(x4)

1

1

2

3108. Mark and drill four (4) Ø5mm holes into

the bedliner vehicle tub front panel usingdimension’s as shown.Rivets must secure to flat form on tub.Apply rust inhibitor to all drilled holes inthe tub sheet metal.Secure with four (4) long stainless steelrivets (FAST0613) as shown.(ref. diagram108).

Diagram: 108 - SECURE FRONT OF BEDLINER

135135 270270


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CLEARABRASION

TAPE

CANOPY NOT SHOWN FOR CLARITY1

1

25% ISOPROPYLALCOHOL

75% WATER


TAILLIGHT

SCREW

109.Using a solution of 25% isopropyl alcoholand 75% water in a spray bottle (not -supplied), thoroughly spray along the topof the tailgate. Remove liner from clearabrasion tape. Working from one end witha 5mm overhang to the side of the tailgate,place clear abrasion tape (TAPE0611-1) onthe tailgate. Trim excess tape leaving a 5mmoverhang at both ends of the tailgate. Whenin position, use a squeegee to push out anyexcess water solution and bubbles. Using scissors, trim tape to end of tailgate.You may need to squeegee a few times.When finished the tape is virtuallyinvisible. To ensure a good finish please take carean do not rush this step. Remove maskingtape. (ref. diagram109).

Diagram: 109 - APPLY ABRASION TAPE

2

110. Open the tailgate and unscrew the two (2) screews holding the taillight.Pull the taillight out and let it hang out onthe wiring harness. (ref. diagram110)

Diagram: 110 - REMOVE REAR LHS TAILIGHT

3

1

WIRING LOOM

WIRING LOOM

CORRUGATED TUBE

HOLE IN THE TUBSHEETMETAL

TAILGATE

PUSHGROMMET

INTOSHEETMETAL

2

111.

Diagram: 111 - FIT WIRING INTO THE TUB SHEETMETAL

TRIMEXCESS CLEARABRASION TAPE

3SQUEEGEE OUT

EXCESS SOLUTIONBUBBLES

4

APPLYCLEAR

ABRASION TAPE

ALIGNBOTTOM EDGE

OF CLEAR ABRASIONTAPE WITH BOTTOM

LIP OF TAILGATE

2

The wiring for the canopy light is attached tothe inside left hand corner of the canopy. Open the rear door and tailgate. First slide the 100mm corrugated tube from (LOOM0050) kit onto the wiring after the grommet, then slide the grommet up to the wiring loom using soapy water. Feed the wiring into the hole in the rear LH side tub sheetmetal. Take care not to damage the wiring loom.Slide the grommet along the loom and fitit to the hole in the sheetmetal. (ref. diagram111).

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7

Diagram: 113 - RUN HARNESS ALONG CHASSIS RAIL

113.

3 CHASSIS RAIL

SEE STEP 114 SEE STEP 115 SEE STEP 117 SEE STEP 116

12

114. Pull the wiring under the chassis from thetail light and secure to the existing wiringwith a short cable tie.(ref. diagram114).

Diagram: 114 - FIT WIRING INTO THE TUB REAR TAIL LIGHT

1

WIRING LOOM

CABLE TIE


WIRINGLOOM

112. Continue threading the wiring into the holeat the bottom of the taillight cavity.Secure the wiring with a short cable tie toa hole at the edge of the sheetmetal.(ref. diagram112).

Diagram: 112 - ATTACH WIRING INTO THE LHS REAR TAILLIGHT

200mm CABLE TIE

IMPORTANT: Take care under thevehicle as the exhaust may be hot.Continue the harness along the chassis rail with existing wiring, up to the front left hand wheel arch as shown. Fit cable ties in sequence listed.Trim excess cable tie length with side cutters.Ensure harness is run in a direct route fromthe rear of the vehicle to the front.IMPORTANT: Keep harness position awayfrom any brake lines or exhaust system.(ref. diagram113).

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116.Feed the canopy harness along thechassis rail as shown.Fit three (3) cable ties along the chassisrail as shown. Trim excess cable tie lengthwith side cutters. IMPORTANT: Wiring harnesses shouldbe positioned away from the exhaustsystem side. Place it on the top outboardside of the chassis rail. (ref. diagram116).

117. Using a draw wire down through the enginebay, attach it to the loose end of the loomand pull up through the engine bay.(ref. diagram117).

Diagram: 116 - ATTACHING WIRING ALONG THE CHASSIES RAIL

Diagram: 117 - DRAWING THE WIRING INTO THE ENGINE BAY

CHASSISRAIL

VIEW LOOKING FROM MIDDLE OF THE VEHICLE TO LH OUTSIDE

FRONT OFVEHICLE

600mm CABLE TIES

115. Feed the wiring loom along the chassisrail above the rear wheel and tuck the loombehind the brackets as shown. Secure witha short cable tie to the existing vehicle’swiring harness. (ref. diagram115).

Diagram: 115 - ROUTING WIRING LOOM AT THE REAR WHEEL

FRONT OFVEHICLE

FRONT OFVEHICLE

600mm CABLE TIE

200mm CABLE TIE

TYRE

CHASSIESRAIL

CHASSIESRAIL

WIRING LOOM

WIRING LOOM

WIRING LOOM

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1

118.Once the wiring is pulled inside the enginebay, use the short cable ties in 3 spots tosecure the wiring to the existing harness.Follow the fire wall to the left side and along the fender towards the battery, as shown. (ref. diagram118).

119. Strip 5mm of the wire insulation on each wireand apply internal diameter ring terminals to ends of each wire.NOTE: The red terminal onto the red wireand black termminal onto the black wire.Crimp terminals to wires solidly.(ref. diagram119).

120. Measure and mark 100mm on the red wireand cut with sidecutters.NOTE: Only cut the red terminal.(ref. diagram120).

Diagram: 118 - ROUTING THE WIRE UNDER THE HOOD

Diagram: 119 - APPLY RING TERMINALS

Diagram: 120 - CUT THE RED WIRE AT 100mm

2 200mm CABLE TIE

BATTERY

WIRING LOOM

8MM RINGTERMINALS

CUT AT 100mm

DRAW WIRINGINTO THE ENGINE

BAY

RED WIRE

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121. Insert both red wires into the Blade Fuse holder, as shown. Close the fuse holder firmly till it clicks together.(ref. diagram121).

122. Slide the 5Amp Blade Fuse into the BladeFuse holder, as shown.(ref. diagram122).

123.

Diagram: 121 - LOCK RED WIRE INTO BLADE FUSE HOLDER

Diagram: 122 - SLIDE FUSE INTO THE HOLDER

Diagram: 123 - CONNECT LOOM TO BATTERY TERMINALS

Position harness and cables as shown.Fit black cable eyelet terminal to the threadon the batteries negative “-” terminal andsecure with (1) M6 ZP hex nut.Lift up the red cap on the batteries positive“+” terminal and fit the red cable eyeletterminal to the thread with (1) M6 ZP hexnut.Refit red cap so it neatly sits over thepositive terminal. (ref. diagram123).FIT BLACK CABLE TERMINAL

& M6 ZP HEX NUT TOBATTERY NEGATIVE TERMINAL

FIT RED CABLE TERMINAL& M6 ZP HEX NUT TO

BATTERY POSITIVE TERMINAL

1 2

--

100mm

REST OF RED LOOM

RED WIRE

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CANOPYLAMP

PLACE FITTING INSTRUCTIONSIN THE CUSTOMERS LOG BOOK

Diagram: 125 - FINAL CLEANING

Clean canopy including all windowsand vehicle thoroughly .Place fitting instructions in theCustomers log book, and ensurepage 27 of these instructions arediscussed with the customer and acopy is given to the customer. (ref. diagram125).

125.

Open the rear door and check that theinternal canopy lamp is operating correctlywhen switched to the ’ON’ position. (ref. diagram124).

Diagram: 124 - CHECK CANOPY LIGHT

OPENREAR DOOR

124.

CHECKCANOPY LAMP

WORKS


OWNERS MANUAL SUPPLEMENTIMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S

VEHICLE SERVICE BOOK.

Warranty Terms - EGR warrants that the 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

Toyota Hilux MY11 Onwards 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.

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. Only use accesory roof racks to cary load on roof.• Do not fill volatile liquid containers while inside canopy such as fuel cans.• VEHICLES FITTED WITH A UTE 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.• Refer other warnings on warning label applied to the rear roof door of the canopy.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) up and rod (narrow end) down.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.DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.Check canopy attachment bolts regularly, at least 1000km and every 3 months.Attachment bolt recommended torque setting must be 9Nm.If removed, bolts must have LOCTITE 243 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 or3M window channel dresser lubricant sparingly. Important: Canopy and tub are not completely water and rust proof. DO NOT use CRC, WD40 or petroleum based lubricants on sliding windows.

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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 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 and lock tension is ok and lower door sash seal, seals to tailgate, 7. Attachment brackets bolts are square and tight (Torque 9Nm)

8. IMPORTANT! Loctite 243 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. 10. Operation of Brake Light (if fitted)

11. Operation of interior light

12. Water Tested for leaks (leaks will occur to tailgate)

13. Clean up of work area

14. Comment

Record Canopy Serial Number: Checked By:

Vehicle Type: SR5 4x2 SR5 4x4 UTE LINER SR 4x2 SR 4x4Double Cab: (A Deck) (A Deck) Additional Accessory (J Deck) (J Deck)

Vehicle received and Checked by Dealer Staff:

Fitted By:

INSTALLATION CHECKLIST

(located on inside LH rear pillar of canopy shell)

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toyota hilux double cab - sr / sr5 canopy, a-deck and j ... fleet cnpy.pdf · toyota hilux double...

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