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

Download Toyota Hilux Double Cab - SR / SR5 Canopy, A-Deck Fleet CNPY.pdf · Toyota Hilux Double Cab - SR

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  • Page 1 of 50 07/12/11

    CP0061

    Place these instructions in vehicles 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 30mm 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 3mm 5mm 9mm 10 and 12mm 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 Nos. :-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)

  • Page 2 of 50 07/12/11

    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

  • Page 3 of 5007/12/11

    CP0061TOYOTA HILUX - CANOPY

    IF A SPORTS BAR IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 1.IF A CABIN GUARD IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 2.

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

  • Page 4 of 5007/12/11

    CP0061TOYOTA HILUX - CANOPY

    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 vehicles(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.

    Diagram: 5 - PROTECT VEHICLE SURFACES

    6.

    Diagram: 6 - REMOVAL OF CABIN GUARD

    Diagram: 4 - SECURE GRINDING PLATE

    PARTIALLY CUT THROUGHOUTER CABIN GUARD BARS

    SECURESACRIFICIAL GRINDING

    PLATE WITH TAPE

    INSERTTIMBER BOARD

  • Page 5 of 5007/12/11

    CP0061TOYOTA HILUX - CANOPY

    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.

    Diagram: 8 - REMOVAL OF CABIN GUARD

    9.

    Diagram: 9 - PREPARE VEHICLE SURFACES

    Diagram: 7 - REMOVAL OF CABIN GUARD

    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

  • Page 6 of 5007/12/11

    CP0061TOYOTA HILUX - CANOPY

    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

    Diagram: 10 - PREPARE VEHICLE SURFACES

    1 REMOVETIMBER BOARDS& CARDBOARD

    PROTECTION MATS

    DEBURRALL SURFACES AROUNDCUT CABIN GUARD BARS

    2

  • Page 7 of 5007/12/11

    CP0061TOYOTA HILUX - CANOPY

    Thoroughly clean and dry

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