3 piece hard tonneau cover tc0220 - egr auto d40 3pc am tc0220.pdf · page 1 of 19 23/11/10 3 piece...

23/11/10page 1 of 19

TC02203 PIECE HARD TONNEAU COVERINSTALLATION INSTRUCTIONS

VEHICLE DESCRIPTION: NISSAN NAVARA D40 DUAL CAB

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

Clean Tonneau Cover with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

Nissan Navara D40 - “EGR” SPOTS BAR(IF PURCHASED FOR THIS FITMENT)

PARTS CHECK SHEET

3 Pce Tonneau Cover with“OEM” Sports Bar

3 Pce Tonneau Cover with“EGR” Sports Bar

PARTS IN SPORTS BAR KIT27

Sports BarMain Top TubeQty - 1

28

Sports BarLHS LegQty - 1

29

Sports BarRHS LegQty - 1

30

Black JoinSleeveQty - 2

31

MouldedBreacket CupQty - 4

32

Foam GasketQty - 4

33

M8x30 PhillipsHead ScrewQty - 4

34

M8x30 ButtonAllen KeyHead ScrewQty - 2

35

M8 SpringWasherQty - 4

36

M8 BlackStar WasherQty - 2

37

M8 Flat WasherQty - 4

38

Tapped BlockQty - 4

This Fitting Instruction where an OEM Sports Bar is referred to, is based on an OEM fitted SportsBar that will need to be removed and hardware retained to re-fit with the 3 Piece Tonneau Coveras detailed in these instructions.This Fitting Instruction where an EGR Sports Bar is referred to, is based on a purchased after-market EGR Sports Bar, and will be built and fitted with the 3 Piece Tonneau Cover as detailed inthese instructions. EGR Sports Bar Parts List is detailed below.

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TC0220Nissan Navara D40 Dual Cab - 3 Piece Tonneau Cover

1

Tonneau CoverQty - 1

PARTS IN MAIN CARTON

PARTS IN FITTING KIT

PARTS CHECK SHEET Nissan Navara D40 - 3 Piece Hard Tonneau Cover

6

Latch Striker(LOCK0023)Qty - 2

7

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

8

Gas StrutStandard(STRT0005-2)Qty - 2

9

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

10

HingeBottom(CLIP2232)Qty - 2

11

HingePin(CLIP2032)Qty - 2

12

Bulb SealHeader Bar(MISC2229-6)Qty - 1

13

Rivet(FAST0433)Qty - 12

14

M6x10 ButtonHead Socket(SCRW0436)Qty - 4

15

M6 ExternalStar Washer(WASH0163)Qty - 4

16

M6 Sem Screw(SCRW0697)Qty - 4

17

M6 Flat Washer(WASH0153)Qty - 8

22

M6x20Phillips Head(SCRW0453)Qty - 4

23

M6 SpringWasher(WASH0103)Qty - 4

18

M6 Hex Nut(NUTS0016)Qty - 4

19

JackingBracket(CLIP2049-1)Qty - 2

20

M8x20 HexHead Bolt(SCRW0665)Qty - 2

21

M8 HexNut(NUTS0217)Qty - 2

4

Header BarAluminium(KIT031962)Qty - 1

5

Lock Keys(Attached toTonneau)Qty - 2

Fitting KitQty - 1

2

LHS CornerPieceQty - 1

3

RHS CornerPieceQty - 1

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.

24

AlcoholWipe(MISC0052)Qty - 4

25

RustInhibitor(MISC2776)Qty - 2

26

FittingInstruction(FIT-TC0220)Qty - 1

FittingInstructions

RustInhibitor

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TOOLS REQUIRED:● Drill● Ø5, Ø7 & Ø10mm Drill Bits● Rivet Gun● 5mm Allen Key● Torque Wrench

● Phillips Screwdriver● Hammer & Centre Punch● Spanners & Sockets● Cleaning Materials● Non-permanent Marker

● Tape Measure● Masking Tape● 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. If an EGR sports bar is to be fitted with the 3 piece tonneau cover to the vehicle please proceed to step 2.In Australia, if an OEM sports bar has been fitted to the vehicle, remove the OEM sports bar and retain all hardware.If an OEM sports bar is going to be fitted with the 3 piece tonneau cover to the vehicle, install the OEM sports bar to vehicle,then remove the OEM sports bar and retain all hardware. See Dia #1.

Diagram #1

2. 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 #2.

Diagram #2

3. Place masking tape in sections along header frame and inner side panels as shown. See Dia #3.

Diagram #3

LAY A SHEETINSIDE THE TUB

3

1

2

ENTIRE LENGTH

ENTIRE LENGTH

4

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

EGR SPORTS BAROEM SPORTS BAR

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4. Fit the Sports Bar Main Tube. See Dia #4.

Diagram #4

5. Secure the Sports Bar together. See Dia #5.

Diagram #5

6. Peel away the protective lining on the foam gaskets and attach them to the moulded bracket cups.Remove the four (4) inside screws from the legs of the Sports Bar and discard. See Dia #6.

Diagram #6

NO POWER TOOLS

27

29 30

29

30

3030

30

28 30

29

27

34

36

27

29

28

TORQUE SETTING: 7Nm

32

28

30 2730

29

31

1

2

32

29

REMOVE INSIDE SCREW

IF FITTING AN EGR SPORTS BAR PLEASE PROCEED WITH STEP 4.IF FITTING AN OEM SPORTS BAR PLEASE PROCEED TO STEP 16.

27

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7. Apply a bead of non-acetic silicon (not supplied) around the inside surface of the moulded bracket cups.Fit the moulded bracket cups to the Sports Bar feet. See Dia #7.

Diagram #7

8. Place Sports Bar on protective mat (not supplied) to avoid scratching. Place corner pieces over ends of Sports Bar legs. See Dia #8.

Diagram #8

9. Loosely attach corner pieces to Sports Bar as shown. See Dia #9.

Diagram #9

3030

27

2928

31

32

28/29

1 2

31NOT SUPPLIED

2

22 23 17

22

23

17

23

17

28

3030 27

29

28

3

2

2

22

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10. Centre punch the side rail according to the dimensions above. Drill a Ø5mm pilot hole followed by a Ø10mm hole. Apply rust inhibitor to the drilled hole. Repeat for the other side of the vehicle. See Dia #10.

Diagram #10

11. Remove the protective lining from the tapped block and attach it to the inside of the side rail as shown. Repeat for the other side of the vehicle. See Dia #11.

Diagram #11

12. Position Sports Bar and corner pieces on bed. Loosely attach front legs of Sports Bar to inner side panels as shown. See Dia #12.

Diagram #12

SIDE VIEW

FRONTTUBPANEL

FRONT

98mm

20mm

2 NOTE: TAPE SIDETO BE PLACEDAGAINST VEHICLE.

TOP EDGEOF SIDE RAIL

38

38

38

110mm

98mm

20mm

Ø10mm

USE RUST INHIBITOR3

1 DRILL Ø5mmPILOT HOLE

2 DRILL Ø10mm HOLE


NO POWER TOOLS

37 35

38

38

3735

33

2/3

4Nm

33

Ø5mm

Ø10mm

28/29SIDE RAIL

1 32Ru

stIn

hibi

tor

25

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13. Mark the Sports Bar rear leg drill holes. See Dia #13.

Diagram #13

14. Remove the Sports Bar from the bed. Drill a Ø5mm pilot hole followed by a Ø10mm hole for the rear Sports Bar leg. Apply rust inhibitor to the drilled hole. Repeat for the other side of the vehicle. See Dia #14.

Diagram #14

15. Remove the protective lining from the tapped block and attach it to the side rail as shown. Repeat for the other side of the vehicle. See Dia #15.

Diagram #15

2/328/29

Ø5mm

Ø10mm SIDE VIEW

FRONTBEDPANEL

FRONT

1 32

110mm

Ø10mm

USE RUST INHIBITOR3

1 DRILL Ø5mmPILOT HOLE

2 DRILL Ø10mm HOLE


DRILLED HOLE FOR FRONT LEGS

2 NOTE: TAPE SIDETO BE PLACEDAGAINST VEHICLE.


38

38

38 TAPPED BLOCK FOR FRONT LEGS(ALREADY INSTALLED)

HOLE DRILLED IN DIAGRAM #14

28/29SIDERAIL

Rust

Inhibi

tor 25

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16. Measure and mark the distances as shown from the rear flange for both the LHS and RHS of the tub with a non-permanentmarker. See Dia #16.

Diagram #16

17. 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 #17.

Diagram #17

18. Measure and mark the distances as shown from the rear flange for both the LHS and RHS of the tub. See Dia #18.

Diagram #18

Rust

Inhibi

tor

REARFLANGE

700mm

37mm

Ø7mm

1 2 3

20mm

DRILL Ø7MM HOLES &APPLY RUST INHIBITOR

25

REARFLANGE

110mm

22mm

10mm

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19. 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 #19.

Diagram #19

20. 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 #20.

Diagram #20

21. Find centre line of tub and mark position on header frame. See Dia #21.

Diagram #21


REMOVE MASKINGTAPE

4

AB

A=B

13

7

Rust

Inhibi

tor

Ø5mm

1 2 3

20mm

25

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22. Find centre of header bar aluminium and position centrally on header frame as shown. See Dia #22.

Diagram #22

23. Mark the eight (8) small 5mm hole positions and remove header bar aluminium.Ignore the other four (4) 9mm holes. See Dia #23.

Diagram #23

24. 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 #24.

Diagram #24

A

B

A=B

4

REMOVEALUMINIUMEXTRUSION

2


REMOVEMASKING

TAPE

4

41

4

4

Rust

Inhibi

tor

Ø5mm

1 2 3

20mm

25

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25. 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 #25.

Diagram #25

26. Slide the tapped plates into the header bar aluminium as shown. See Dia #26.

Diagram #26

27. 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 #27.

Diagram #27

13

4

9

9

4

10

4

10

15

14

9

4

NOT SUPPLIED

1

2

2

3

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28. Position the hinge brackets 274mm from the sides of the tub as shown. See Dia #28.

Diagram #28

29. Tighten the hinge brackets firmly as shown. Tighten to torque 8Nm. See Dia #29.

Diagram #29

30. If fitting an EGR sports bar please proceed to step #31. If fitting an OEM sports bar, place it on protective mat (not supplied) to avoid scratching.Loosely attach corner pieces to sports bar using the M6 phillips head screws, M6 flat washers and M6 spring washers as shown.See Dia #30.

Diagram #30

OEMSPORTS BAR

PROTECTIVE MATCORNER PIECE LHS OEM SPORTS BAR

3

2

22

23 2

17

RHS

274mm

10

1 TORQUE 8Nm10

LHS

10

274mm

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31. Carefully position sports bar and corner pieces on tub. See Dia #31.

Diagram #31

32. For “OEM” sports bar, loosely attach front legs of sports bar with retained hardware to inner side panels as shown.For “EGR” sports bar, loosely attach front legs of sports bar using hardware from sports bar kit to inner side panels as shown.See Dia #32.

Diagram #32

33. For “OEM” sports bar, loosely attach jacking brackets to rear sports bar legs and inner side panels using retained Sports Barhardware. Tighten all sports bar bolts to torque setting 8Nm.For “EGR” sports bar, loosely attach jacking brackets to rear sports bar legs and inner side panels using hardware from sports barkit to inner side panels as shown. Tighten all sports bar bolts to torque setting 8Nm. See Dia #33.

Diagram #33

NO POWER TOOLS

NO POWER TOOLS

TIGHTEN ALL SPORTS BARBOLTS TO TORQUE 8Nm

“OEM” SPORTS BAR

“OEM” SPORTS BAR “EGR” SPORTS BAR

“OEM” SPORTS BAR “EGR” SPORTS BAR

“EGR” SPORTS BAR

2/3

19 19

38 3735

33

33

333738

383537 35 33

20

1 1

2/3 2/3

37 3538

2/3

19

2/3

2/3

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34. Thread M8 nut onto M8 hex head bolt. Thread screw (three turns only) into tapped hole in the jacking bracket as shown.See Dia #34.

Diagram #34

35. Clean the top of the header bar aluminium with the alcohol wipe & wipe away any residue with a clean cloth. See Dia #35.

Diagram #35

36. 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 #36.

Diagram #36

13mm

LHS SHOWN

ALCOHOLWIPES

1 2

1 2

ALCOHOLWIPES

21

2/3

2/3

21

20

20

4

4

12

12

30

24

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38. 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 #38.

Diagram #38

NEXT DIAGRAM

2

RE-TORQUE 5NmLOOSEN HINGE SCREWS

TO ADJUST TONNEAUPOSITION IF NECESSARY

2

ENSURECLEARANCE

TO TUB

1

1

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

37. 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 #37.IMPORTANT: Ensure hinge pins clip into retaining leg on lower hinges. If misaligned, seal can be pushed forward from inside of the tub.

Diagram #37

2

1

1111

1

1

3

1212

1

1

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39. Attach gas struts. Ensure the narrow end mounts to the vehicle, and the wide end mounts to the tonneau cover. See Dia #39.

Diagram #39

40. 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 #40.

Diagram #40

41. 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 #41.

Diagram #41

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

INSPECTION COVERPLASTIC RETAINER

CLIPSPULL RODS

REMOVE INSPECTIONCOVER

2

1

RELEASE PLASTICRETAINER CLIPS

3 UNCLIP PULL RODSFROM PLASTICRETAINER CLIPS

4

TO REMOVE:

18 17

FIT ITEM 17 & 18 THROUGH THE OPENINGWHERE THE TAIL LIGHT WAS REMOVED

6

16

1 2

7

8

ENSURE NARROWEND OF GAS STRUT

MOUNTS TO VEHICLE

3 ENSURE WIDE ENDOF GAS STRUT MOUNTS

TO TONNEAU COVER

8

1

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42. Close Tonneau Cover and inspect locking mechanism. Ensure the latch hits the striker bracket centrally. If it DOES, proceed to Diagram #43 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 #42. Note: Tonneau Cover has 2 stage locks. Ensure Tonneau engages with second stage of the latch.

Diagram #42

43. 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 #43.

Diagram #43

44. Check surfaces of corner pieces and tonneau cover are even.For any adjustment, raise or lower jacking screw until even. Tighten lock nut.Replace the vehicle’s tail lights and re-connect the wiring. Check operation of vehicles tail lights. See Dia #44.

Diagram #44

NO POWER TOOLS2083

21

INCORRECT

INSPECT LATCHENGAGEMENT

CORRECT

2

1

ADJUST STRIKER BRACKET3 ADJUST LATCHMECHANISM

4

SCREWS

TORQUE 4Nm

ADJUST6

REPLACE TAIL LIGHTS& RE-CONNECT WIRING CHECK OPERATION

OF VEHICLE TAIL LIGHTS

3

1

4

2

16

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

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

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REMOVAL OF TONNEAU COVER

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

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:

17

8

1111

10 10

2

3 piece hard tonneau cover tc0220 - egr auto d40 3pc am tc0220.pdf · page 1 of 19 23/11/10 3 piece...

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