1 piece hard tonneau cover installation instructions · 2016. 6. 6. · tc0219 page 3 of 12...

VEHICLE DESCRIPTION: NISSAN NAVARA D40 DUAL CAB

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PLACE THESE INSTRUCTIONS IN VEHICLE’S GLOVE BOX AFTER INSTALLATION IS COMPLETE.

1 PIECE HARD TONNEAU COVERINSTALLATION INSTRUCTIONS

23/11/10

Clean Tonneau Cover with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

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.

1

Tonneau CoverQty - 1

PARTS IN MAIN CARTON

PARTS IN FITTING KIT

PARTS CHECK SHEET Nissan Navara D40 - 1 Piece Hard Tonneau Cover

4

Latch Striker(LOCK0023)Qty - 2

5

Gas StrutBracket 10mm(CLIP2034-1)Qty - 2

6

Gas StrutStandard(STRT0005-2)Qty - 2

7

Tapped Plate(Hinge)(CLIP1988-1)Qty - 2

8

HingeBottom(CLIP2232)Qty - 2

9

HingePin(CLIP2220)Qty - 2

10

Bulb SealHeader Bar(MISC2229-1)Qty - 1

11

Rivet(FAST0433)Qty - 12

12

M6x10 ButtonHead Socket(SCRW0436)Qty - 4

13

M6 ExternalStar Washer(WASH0163)Qty - 4

14

M6 Sem Screw(SCRW0697)Qty - 4

15

M6 Flat Washer(WASH0153)Qty - 4

16

M6 Hex Nut(NUTS0016)Qty - 4

17

AlcoholWipe(MISC0052)Qty - 4

18

RustInhibitor(MISC2776)Qty - 2

19

FittingInstruction(FIT-TC0219)Qty - 1

FittingInstructions

2

Header Bar Aluminium(KIT028374)Qty - 1

3

Lock Keys(Attached to Tonneau)Qty - 2

Fitting KitQty - 1

RustInhibitor

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Nissan Navara D40 Dual Cab - 1 Piece Tonneau Cover

TOOLS REQUIRED:● Drill● Ø5, Ø6 & Ø7mm Drill Bits● Rivet Gun● 5mm Allen Key● Torque Wrench

● Phillips Screwdriver● Hammer & Centre Punch● Spanners & Sockets● Side Cutters● Non-permanent Marker

● Tape Measure● Masking Tape● Draw Wire● Non-Acetc Silicon● Silicon Dispenser

WARNING!When in the closed position, Tonneau Cover must be locked and tail gate must be closed! Failure to do so could result in unexpected opening of the Tonneau Cover from sudden wind gusts, which could cause damage to the vehicle and/or your Tonneau Cover!

MAINTENANCE:• For Tonneau Cover products that have a textured exterior surface, wash the Tonneau Cover and clean dirt out of the texture with a soft brush and apply a commercially available automotive car polish to maintain product shine. If fuel is splashed onto the Tonneau Cover immediately wash it off with car washing detergent and water. If staining is apparent polish the stain out with a commercially available car polish such as "Kitten car polish".• Only use cleaners, waxes, or products that are labelled safe for use on plastics. Avoid the use of any chemicals to clean your Tonneau Cover unless labelled safe for plastics. Avoid use of abrasive type cleansers as they may dull the finish.• The gas struts are self lubricating and should only be cleaned occasionally with a damp cloth. Premature seal failure will result if solvents or lubricants are used to clean struts. • The locking mechanisms & Latches only require occasional lubrication with Graphite Powder. DO NOT use any other lubricants or oils. • Using alternative products will VOID Warranty.• All installation hardware and fasteners must be checked every so often for tightness.

TONNEAU COVER - 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.• Do not stand/sit or rest heavy objects on Tonneau Cover.• Humans or animals are not to be under the closed Tonneau Cover at any time.• Securely lock Tonneau Cover before operating vehicle.• Do not carry open volatile chemicals with Tonneau Cover installed.• If contact with volatile chemicals occurs clean Tonneau Cover with mild detergent and water solution.• Do not cycle remote key fob continuously, or the actuator for operation of the remote locking system will burn out.• Recommend installation by 2 people.• Approximate fitting time is 2 hours.

PAINTING INSTRUCTIONS: (IF UNPAINTED)• If product surface is textured painting is not required.• Sand Tonneau Cover prior to painting, recommend 500 grit using an orbital type sander.• Prior to painting, clean all surfaces to be painted using clean water and a mild detergent, do not use lacquer thinner or any solvent based products. Wipe completely dry. • Best results will be achieved by wiping the areas to be painted with a tack rag just prior to painting.• Select a top coat and clear paint that is suitable for ABS (Acrylonitrile-Butadiene-Styrene).• Automotive paint systems, such as Acrylics or Two Packs, can be applied directly to the components. However, some paints may require a primer. If recommendations on paint specification are not followed, cracking of the part or degradation to the material may result. In all paint systems, aromatic hydrocarbons and alkalies are best avoided to reduce damage to the material properties.• If using a paint system which requires baking, do not expose the product to temperatures above 70° C (155° F). • Allow a minimum of 8 hours after baking before installation on the vehicle.

Warranty TermsEGR warrants that the ABS Tonneau Cover EGR will be free from defects in material and workmanship for a period of three (3) years from the retaildate of purchase. The gas struts are warranted for one (1) year from the retail date of purchase. This warranty only applies to the original purchaserand is nontransferable. Warranty must be claimed with original sales receipt for proof of purchase.

ExclusionsThis warranty does not cover failure due to neglect, improper installation including any modifications to installation hardware, operating the vehiclewith your EGR Tonneau Cover in the open position, alterations, addition of equipment, abuse, accident, corrosion, normal wear and tear, lack ofmaintenance, and exposure to chemicals that are not safe for plastics. Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Tonneau Cover is sole responsibilityof the vehicle owner and operator. Paint wear to the vehicle bed can happen with any Tonneau Cover and is the sole responsibility of the vehicle owner.Paint damage to your vehicle is not covered under this warranty.

DisclaimerIn the event that your EGR Tonneau Cover is found to be defective under the terms of this warranty, it is at the discretion of EGR to repair or replacethe defective part. Transportation costs and labor are not associated with this warranty claim.

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1. Clean installation area with a dry, clean cloth.Lay a sheet inside the tub to catch metal drill swarf from installation.Remove the vehicle’s tail lights, disconnect the wiring and store in a safe place to re-fit at a later stage. See Dia #1.

Diagram #1

2. Place masking tape in sections along header frame and inner side panels as shown. See Dia #2.

Diagram #2

3. Measure and mark the distances as shown from the rear flange for both the LHS and RHS of the tub with a non-permanent marker. See Dia #3.

Diagram #3

LAY A SHEETINSIDE THE TUB

3

1

2

800mm

ENTIRE LENGTH

4

COMPLETELY REMOVE TAIL LIGHTS,DISCONNECT WIRING & STORE IN A SAFE PLACE

REARFLANGE

110mm

22mm

Rust

Inhibi

tor

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REARFLANGE

700mm

37mm

Ø7mm

1 2 3

20mm

DRILL Ø5MM HOLES &APPLY RUST INHIBITOR


REMOVE MASKINGTAPE

4

4. Centre punch the previously marked positions, drill Ø7mm holes and apply rust inhibitor to the drilled holes.Repeat process for the other side. See Dia #4.

Diagram #4

5. Measure and mark the distances as shown from the rear flange for both the LHS and RHS of the tub. See Dia #5.

Diagram #5

6. Centre punch the previously marked positions, drill Ø5mm holes and apply rust inhibitor to the drilled holes.Repeat process for the other side.Finally, remove the masking tape from the inside of the side rails. See Dia #6.

Diagram #6

18

Rust

Inhibi

tor

Ø5mm

1 2 3

20mm

18

10mm

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REMOVEALUMINIUMEXTRUSION

2


REMOVEMASKING

TAPE

7. Position the Gas Strut Brackets to correspond with the Ø5mm drilled holes in the side rail.Attach the gas strut brackets to the side rails using two (2) rivets per side as shown. See Dia #7.

Diagram #7

8. Position header bar on header frame as shown.Mark the eight (8) small 5mm hole positions and remove header bar aluminium.Ignore the other four (4) 9mm holes. See Dia #8.

Diagram #8

9. Centre punch the previously marked locations, drill Ø5mm holes and apply rust inhibitor to the drilled holes.Finally, remove the masking tape from the inside of the header frame. See Dia #9.

Diagram #9

2

11

5

1

2

4

Rust

Inhibi

tor

Ø5mm

1 2 3

20mm

18

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10. Slide the tapped plates into the header bar aluminium as shown. See Dia #10.

Diagram #10

11. Loosely attach the two (2) hinge brackets to the tapped plates in the header bar aluminium with four (4) M6x10 button headsocket screws and M6 external star washers as shown. See Dia #11.

Diagram #11

12. Apply non-acetic silicon to the length of the header bar aluminium, on the underside that contacts the top of the header frame.Attach the header bar aluminium to the header frame using the rivets as shown.Apply non-acetic silicon between the header bar aluminium and header frame at the ends as shown. See Dia #12.

Diagram #12

2

7 7

2

8

2

8

13

12

7

2

NOT SUPPLIED

1

2

3

11

2

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RHS

13. Position the hinge brackets 274mm from the sides of the tub as shown. See Dia #13.

Diagram #13

274mm

8

LHS

8

274mm

15. Clean the top of the header bar aluminium with the alcohol wipe & wipe away any residue with a clean cloth. See Dia #15.

Diagram #15

14. Tighten the hinge brackets firmly as shown. Tighten to torque 8Nm. See Dia #14.

Diagram #14

1 TORQUE 8Nm8

ALCOHOLWIPES

17

1 2ALCOHOLWIPES

2

17

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1

CLICK!LOWERHINGE BRACKET

4 5

IMPORTANT: Ensure vehicles’s tailgate is opened before installing Tonneau Cover, andremains open until lock striker is fitted and locking mechanism is adjusted correctly.

TONNEAU SEAL FITMENTOVER HEADER RAIL SEAL

16. Fit the bulb seal to header bar aluminium between corner pieces as shown. Remove adhesive tape liner and press firmly toensure maximum adhesion. See Dia #16.

Diagram #16

17. Open vehicle’s tail gate and keep it open until locking mechanism has been adjusted correctly.Two people are required to carry out the fitment of the tonneau cover.Fit tonneau cover to vehicle ensuring seal at the front of the tonneau cover sits correctly over the header rail seal as shown.Secure hinges with hinge pins as shown. See Dia #17.IMPORTANT: Ensure hinge pins clip into retaining leg on lower hinges. If misaligned, seal can be pushed forward from inside of the tub.

Diagram #17

2

1

99

1

1

3

1010

1

1

1 2

2

10

10

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NEXT DIAGRAM

2

RE-TORQUE 5NmLOOSEN HINGE SCREWS

TO ADJUST TONNEAUPOSITION IF NECESSARY

2

ENSURECLEARANCE

TO TUB

1

18. Close and check Tonneau Cover is central to vehicle and the sides of Tonneau Cover do not contact the vehicle bed rail.Adjust position if necessary by loosening the top hinge screws and re-positioning Tonneau Cover to fit centrally on vehicle.Re-tighten hinges to 5Nm torque. See Dia #18.

Diagram #18

1

TO REMOVE:

19. Attach gas struts. Ensure the narrow end mounts to the vehicle, and the wide end mounts to the tonneau cover. See Dia #19.

Diagram #19

20. Position the lock striker bracket to correspond with previously drilled holes.Align and loosely attach the lock striker bracket using two (2) M6 sem screws, M6 flat washers & M6 hex nuts as shown.Fit the M6 flat washers & M6 hex nuts through the opening where the tail light was removed.Repeat process for the other side of the vehicle. See Dia #20.

Diagram #20

16 15

FIT ITEM 24 & 27 THROUGH THE OPENINGWHERE THE TAIL LIGHT WAS REMOVED

4

14

1 2

5

6

ENSURE NARROWEND OF GAS STRUT

MOUNTS TO VEHICLE

3 ENSURE WIDE ENDOF GAS STRUT MOUNTS

TO TONNEAU COVER

6

1

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IMPORTANT: Ensure vehicles’s tailgate remains open whilst adjusting Tonneau Cover locking mechanism.

21. Open Tonneau Cover and remove inspection cover by removing scrivets and rotating cover anti-clockwise. Release plastic retainer clips and unclip pull rods as shown. See Dia #21.

Diagram #21

1

INSPECTION COVERPLASTIC RETAINER

CLIPSPULL RODS

REMOVE INSPECTIONCOVER

2 RELEASE PLASTICRETAINER CLIPS

3 UNCLIP PULL RODSFROM PLASTICRETAINER CLIPS

4

IMPORTANT: Ensure that the Tonneau Cover locking mechanism is functioning correctly before closing tailgate.

INCORRECT

INSPECT LATCHENGAGEMENT

CORRECT

2

1

ADJUST STRIKER BRACKET3 ADJUST LATCHMECHANISM

4

1

ENGAGE LOCK

LATCH MECHANISM

PRESS LATCHUPWARDS

ROTATE PULL RODS

CLOCKWISE = SHORTENANTI-CLOCKWISE = LENGTHEN

“CLICK”

2 ADJUST LENGTH OFPULL RODS BY ROTATION

3 4

REPLACE INSPECTION COVER6

TEST LOCKING MECHANISM5

RETAINERCLIPS

INSPECTIONCOVER

LOCK PLASTIC RETAINER CLIPSBACK IN POSITION

SCREWS

TORQUE 4Nm

ADJUST

22. Close Tonneau Cover and inspect locking mechanism. Ensure the latch hits the striker bracket centrally. If it DOES, proceed to Diagram #23 below. If it DOES NOT, adjust the striker bracket accordingly by loosening the M6 screws and moving the bracket up or down as shown. You may also need to adjust the latch mechanism by loosening the screws and moving it left or right as shown.See Dia #22. Note: Tonneau Cover has 2 stage locks. Ensure Tonneau engages with second stage of the latch.

Diagram #22

23. Open the Tonneau Cover and engage the lock by pressing upwards on the latch. Adjust pull rods so that they clip back into the retainer clips correctly. Do this by rotating them clockwise to shorten them or anti-clockwise to lengthen them. Clip pull rods and retainer clips back into position. Test lock by pressing the button on top of Tonneau Cover. If latch mechanism DOES NOT release, return to Step 3 and shorten the pull rods. If it DOES release, replace inspection cover. See Dia #23.

Diagram #23

4

14

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24. Replace the vehicle’s tail lights and re-connect the wiring. Check operation of vehicles tail lights. See Dia #24.

Diagram #24

REPLACE TAIL LIGHTS &RE-CONNECT WIRING

CHECK OPERATIONOF VEHICLE TAIL LIGHTS

1

2

REMOVAL OF TONNEAU COVER

TO REPLACE THE TONNEAU COVER:Reverse the sequence and the procedures of the three (3) Diagrams above.

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HINGE PIN

1 32

1. Open Tonneau Cover and detach gas struts from the vehicle by inserting a small screw driver and adjusting the spring clip onthe strut as shown. See Dia #1. NOTE: Do not remove the spring clip. Only a small amount of levering is required to detach.

Diagram #1

2. Remove hinge pins and then remove the Tonneau Cover as shown. See Dia #2.

Diagram #2

TO REMOVE:1

5

6

99

8 8

2

1 piece hard tonneau cover installation instructions · 2016. 6. 6. · tc0219 page 3 of 12...

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