installation instructions nissan navara d40 ... - egr auto d40... · page 3 of 22 16/01/14 cp0019d...

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16/01/14 Page 1 of 22 CP0019d Place these instructions in vehicle’s glove box after installation is complete Clean Canopy with a mild detergent and water solution. Do not use abrasive cleaners or solvents. Care Instructions: Installation Time: 1 Hour (Approximately) 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. • Recommend installation by 2 people. 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 - 0-10Nm • Non Permanent Marker • Masking Tape • Cleaning Cloths / Rags • Steel Rule and Tape Measure • Scissors (Sharp) • Knife (Sharp) • Squeegee • Metal Primer • Light Gauge Plastic Coated Draw Wire • Small Round File or Deburring Tool • Ø5mm Drill Bit • Rivet Gun for Stainless Steel Rivets NISSAN NAVARA D40 Double Cab - RX / ST / ST-X (with & without Nissan Genuine Bed Liner) (For Australia: 2005 Production Onwards for ST & ST-X) (January 2009 Production Onwards for RX) CANOPY INSTALLATION INSTRUCTIONS PLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES. IF FITTING THE CANOPY TO A 2006 Production Onwards ‘ST-X’ MODEL , THEN ADDITIONAL SUPPLEMENTARY KIT PART No:- D40STX-CNPY-HARN WITH FITTING INSTRUCTIONS (CP0020) WILL BE REQUIRED. This Canopy is designed to suit the Double Cab (4x2 & 4x4) RX, ST & ST-X Navara D40. Sports Bars MUST be removed & returned to Customer with all hardware components if required. Cabin Guards MUST be removed & discarded. This canopy is only designed to work with unboltable Cabin Guards on on RX models from January 2009 Release. This Fitting Instruction where a Bed Liner is referred to, is based on - Nissan Genuine Under Rail Bed Liner Accessory only.

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16/01/14Page 1 of 22

CP0019d

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

Clean Canopy with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

Installation Time:1 Hour (Approximately)

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.• Recommend installation by 2 people.

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 - 0-10Nm

• Non Permanent Marker• Masking Tape• Cleaning Cloths / Rags• Steel Rule and Tape Measure• Scissors (Sharp)• Knife (Sharp)• Squeegee• Metal Primer• Light Gauge Plastic Coated Draw Wire• Small Round File or Deburring Tool• Ø5mm Drill Bit• Rivet Gun for Stainless Steel Rivets

NISSAN NAVARA D40 Double Cab - RX / ST / ST-X(with & without Nissan Genuine Bed Liner)

(For Australia: 2005 Production Onwards for ST & ST-X)(January 2009 Production Onwards for RX)

CANOPYINSTALLATION INSTRUCTIONS

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

IF FITTING THE CANOPY TO A 2006 Production Onwards ‘ST-X’ MODEL ,THEN ADDITIONAL SUPPLEMENTARY KIT PART No:- D40STX-CNPY-HARN

WITH FITTING INSTRUCTIONS (CP0020) WILL BE REQUIRED.

This Canopy is designed to suit the Double Cab (4x2 & 4x4) RX, ST & ST-X Navara D40.Sports Bars MUST be removed & returned to Customer with all hardware components if required.Cabin Guards MUST be removed & discarded. This canopy is only designed to work withunboltable Cabin Guards on on RX models from January 2009 Release.This Fitting Instruction where a Bed Liner is referred to, is based on -Nissan Genuine Under Rail Bed Liner Accessory only.

Page 2 of 22 16/01/14

CP0019dNISSAN NAVARA D40 - CANOPY

PARTS CHECK SHEET NISSAN NAVARA D40 CANOPY

CanopyQty - 1

PARTS IN MAIN CARTON

Front Tub StopExtrusion(ALUM0038-10)Qty - 1

Fitting Kit(KIT032043)Qty - 1

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

Kit - RailClamps(CNPY0007)Qty - 6

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

Tape EPDM43005.5mx20mmx6mm(TAPE0386)Qty - 1

Screw M6x30Hex Head SS304(SCRW0824)Qty - 4

M6 Flat WasherOD. 19mm(WASH0169)Qty - 8

M6 Nyloc NutSS304(NUTS0016)Qty - 4

Bulb Seal 70mmCut Length(MISC2600-1)Qty - 2

Vehicle WiringPatch Harness(LOOM0027)Qty - 1

PARTS IN FITTING KIT (KIT032043)

PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0027)

Cable Ties(3) Long(27) ShortQty - 30

Adhesive TiePadQty - 1

10 Amp BladeFuseQty - 1

Rivet SS304ST-ST 6-6(FAST0505)Qty - 8

Clear Tape Pad50x30mm AbrasionResistant(TAPE0011)Qty - 6

Front Tub SpacerExtrusion(ALUM0038-9)Qty - 1

LH TubRe-InforcementBracket(CNPY0027PC-LH)Qty - 1

RH TubRe-InforcementBracket(CNPY0027PC-RH)Qty - 1

M8x25 HexHead Bolt(SCRW0696)Qty - 10

M8 FlatWasher(WASH0171)Qty - 12

M8 SpringWasher(WASH0152)Qty - 10

M8 Hex NutSS304(NUTS0217)Qty - 2

RustInhibitor

Alcohol Wipe(MISC0052)Qty - 4

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.

Rust InhibitorSatchel(MISC2776)Qty - 1

Primer Stick(MISC1365)Qty - 5

Vehicle WiringPatch Harness Kit(LOOM0027)Qty - 1

FittingInstruction(FIT-CP0019d)Qty - 1

FittingInstruction

104x35mmLabel Sticker(LABL1441)Qty - 1

16/01/14Page 3 of 22

CP0019dNISSAN NAVARA D40 - 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 4.

Remove the four (4) 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.

Remove and retain the twelve (12)hardware items securing the cabin guardto the front rail as shown. (ref. diagram2).

2.

Diagram: 2 - REMOVE HARDWARE SECURING CABIN GUARD

Carefully remove the cabin guard takingcare to avoid scratching the paintwork.(ref. diagram5).OPTIONAL: If customer requests paint allareas left exposed as primed sheetmetal.Painting is preferred to prevent rust.(ref. diagram3).

3.

Diagram: 3 - REMOVE CABIN GUARD

Diagram: 1 - REMOVE SPORTS BAR & HARDWARE

REMOVEHARDWARE

REMOVE &RETAIN

HARDWARE

1

2

5mm

REMOVECABIN GUARD

12mm

16/01/14Page 4 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

At the rear left hand side of the vehicle locate the existing harness connectors and disconnect them.For RX, ST & pre 2006 ST-X vehicle’s connect the tail lamp connectors to the vehicle harness (LOOM0027)connectors as shown. For 2006 Production Onwards ST-X vehicle’s, you will need to fit D40STX-CNPY-HARNusing Fitting Instructions CP0020 as detailed. Run the vehicle harness across the back of the vehicle to the righthand chassis rail, then follow the chassis rail to the front right hand wheel arch. Ensure the harness is positioned awayfrom the exhaust system. Ensure the canopy connector is positioned on the chassis rail between the tub and the cabinas shown. Secure the vehicle harness with cable ties spaced 300mm - 400mm apart. Position cable ties away fromfuel lines, brake cables,moving parts and flexible mounts to body. Trim excess cable tie length with side cutters.Ensure harness is run in a direct route from the rear of the vehicle to the front. (ref. diagram4).

4.

Diagram: 4 - CONNECT & RUN VEHICLE HARNESS UNDER THE VEHICLE

RUNVEHICLE HARNESS

ALONG CHASSIS RAIL

APPLYCABLE TIES EVERY

300-400MM

FUSE TERMINALCONNECTION

RIGHT HAND SIDE OF VEHICLE

REAR LEFT HANDSIDE OF VEHICLE

FRONT OF VEHICLE

RUNVEHICLE HARNESS ACROSSTHE REAR OF THE VEHICLE

POSITION CANOPYCONNECTOR UNDERTHE GAP BETWEENTHE CABIN & TUB

DISCONNECTEXISTING VEHICLE

HARNESS CONNECTORS

1

CONNECTEXISTING HARNESS CONNECTORS

TO THE VEHICLE HARNESSCONNECTORS

CANOPY VEHICLEHARNESS (LOOM0027)

EX

ISTI

NG

VE

HIC

LE H

AR

NE

SS

CO

NN

EC

TOR

S

2

3

4

5

6

FOR 2006 PRODUCTION ONWARDSST-X VEHICLE’S REFER TO

FITTING INSTRUCTION CP0020KIT NUMBER - D40STX-CNPY-HARN

FOR RX, ST & PRE 2006 ST-XVEHICLE’S SEE BELOW

16/01/14Page 5 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Open and secure the bonnet.Feed a draw wire down through the enginebay in the rear right hand corner where theinner right hand front quarter panel meetsthe firewall as shown.From under the left hand front wheel arch,attach the end of the vehicle harness to thedraw wire. Using two (2) people, one personfeeding the vehicle harness and the secondperson to pull the draw wire until theharness is at the top of the engine bay.Remove the draw wire.(ref. diagram5).

5.

Remove the cover on fuse box carefullyso you do not break the clipping tags.Remove the cable clamp securing theharnesses in the fuse box carefully soyou do not break the clipping tags.(ref. diagram6).

Remove the horn fuse as shown (for RXand ST vehicles only).The horn fuse is in a different location onST-X vehicles and does not need to beremoved. (ref. diagram7).

6.

Diagram: 6 - REMOVE FUSE BOX COVER & CABLE CLAMP

7.

Diagram: 7 - REMOVE HORN FUSE FOR RX & ST VEHICLES ONLY

Diagram: 5 - USING A DRAW WIRE PULL HARNESS INTO ENGINE BAY

1 OPEN BONNET

FEED DRAW WIRE2

ATTACHVEHICLE HARNESS

CHASSISRAIL

WHEEL ARCHRH FRONT

REMOVEFUSE BOX

COVER

1 REMOVECABLE CLAMP2

3

FRONT OF VEHICLE

FRONT OF VEHICLE

FRONT OF VEHICLE

REMOVEHORN FUSERX & ST

VEHICLE’S ONLY

16/01/14Page 6 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Release the 3 clips holding the fuseholder as shown.Remove the fuse holder from the fuse box.(ref. diagram8).

8.

Diagram: 8 - RELEASE & REMOVE THE FUSE HOLDER

CONTINUED OVER THE PAGE

2 REMOVE FUSE HOLDER1 RELEASE ALL 3 CLIPSHOLDING THE FUSE HOLDER

16/01/14Page 7 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Route canopy harness with existing harnesses as shown. Connect the canopy harness terminal to a spare fuse holeas shown. Fit the 10 amp fuse from the wiring harness hardware kit, to the spare fuse hole that lines up with canopyharness terminal as shown. (ref. diagram9).

9.

Diagram: 9 - FIT CANOPY HARNESS & FUSE TO FUSE HOLDER

RX VEHICLE ONLY

ST VEHICLE ONLY

ST-X VEHICLE ONLY

FIT10 AMPFUSE

3

ROUTECANOPY

HARNESS

CONNECTTERMINAL TOSPARE FUSE

HOLE

1

2

ROUTECANOPY

HARNESS

CONNECTTERMINAL TOSPARE FUSE

HOLE

1

2

ROUTECANOPY

HARNESS

CONNECTTERMINAL TOSPARE FUSE

HOLE

1

2

FIT10 AMPFUSE

3

FIT10 AMPFUSE

3

CANOPYHARNESS

CANOPYHARNESS

CANOPYHARNESS

16/01/14Page 8 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Replace the fuse holder ensuring the (3)clips, clip back into position.Gently pull fuse holder to ensure it isclipped in correctly and can not beremoved.For RX and ST vehicles replace previouslyremoved horn fuse. (ref. diagram11).

10.

Diagram: 10 - REPLACE THE FUSE HOLDER & HORN FUSE

Diagram: 12 - NEATLY SECURE HARNESS & CLOSE BONNET

Diagram: 11 - REPLACE FUSE BOX COVER & CABLE CLAMP

11.

12.

Replace the cable clamp to secure theharnesses in the fuse box and ensurethe clipping tags are engaged.Replace the cover on fuse box and ensurethe clipping tags are engaged.(ref. diagram11).

Use cable ties to neatly position andsecure vehicle harness.Close the bonnet.(ref. diagram12).2 CLOSE

BONNET

NEATLY POSITION HARNESS& SECURE WITH CABLE TIES

1

2

REPLACEFUSE BOX

COVER

2REPLACECABLE CLAMP1

REPLACE HORN FUSERX & ST VEHICLE’S ONLY

1 REPLACE FUSE HOLDER,ENGAGE ALL 3 CLIPS

CANOPYHARNESS

CANOPYHARNESS

CANOPYHARNESS

CANOPY HARNESS

16/01/14Page 9 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

POSITIONCARDBOARD TUBPROTECTION MAT

1

2

Diagram: 14 - MARK & CUT-OUT BED LINER

Diagram: 13 - CLEAN & DRY INSTALLATION AREAS

13.

14.

15.

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).

For “RX” vehicle’s only, with a genuineunder rail bed liner fitted.Carefully remove the bed liner.Mark out the bed liner using the existingedge and bottom of radius as shown.Cut out the marked area on the bed liner.Remove all sharp edges and burrs.Repeat process for the other side.Do Not re-install the bed liner at this stage.(ref. diagram14).

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. (ref. diagram15).

RIGHT HAND SIDEOF BED LINER

FRONT OF

BED LINER

MARKA LINE USING THEEXISTING EDGE

MARKA LINE USING THE

BOTTOM EDGE OF THERADIUS & EXTEND TOEDGE OF BED LINER

CUT-OUTMARKED AREAOF BED LINER

1 REMOVE & RETAINBED LINER &

ALL HARDWARE

2

2 4 5

34

3

1

2

TOP VIEW OF FRONT TUB RAIL

APPLYPRIMER STICK TO SHADED AREA

ACROSS FULL WIDTH OF FRONT TUB RAIL

2

Diagram: 15 - CLEAN AND PRIME TUB RAIL

16/01/14Page 10 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Diagram: 16 - “RX” - FIT TUB STOP & RE-INFORCEMENT BRACKETS

16. For “RX” vehicle’s only.If the bare metal areas left from removingthe cabin guard have not been painted,complete this step to fit the label sticker.Using alcohol wipe provided, clean thebare metal area around the lower hole onthe side panel where the cabin guardhardware was removed and wipe awayresidue with a dry clean cloth.Cut black label sticker (LABL1441) in halfas shown.Remove adhesive liner from label stickerand adhere over the hole and bare metalsurface on the side panel as shown.Repeat process for the other side of thevehicle. (ref. diagram16).

Diagram: 17 - “RX” - FIT TUB STOP & RE-INFORCEMENT BRACKETS

17. For “RX” vehicle’s only.Position the front tub stop extrusion(ALUM0038-10) on the front tub rail andsecure loosely using previously retainedcabin guard bolts through the four (4)middle slots as shown.Fit LH/RH re-inforcement brackets(CNPY0027) to the front tub stop extrusionand secure loosely using one (1) retainedcabin guard bolt, M8 spring washer andM8 flat washer through the inboard slot,one (1) M8x25 hex bolt, M8 spring washer,two (2) M8 flat washers and one (1) M8hex nut through the outboard slot, andone (1) M8x25 hex bolt, M8 spring washerand M8 flat washer through the slot in theside of the bracket into the side panel asshown (for both sides). Centre front tub stop extrusion to tub, andalign the top face of the front tub stopextrusion to the top of the front tub rail andtighten all ten (10) bolts to Torque 9Nm. Re-install bed liner if removed previously.(ref. diagram17).

9Nm

15mm

15mm

VEHICLE CABIN NOTSHOWN FOR CLARITY

2

2 CUT LABELSTICKER IN HALF

1

FITLABEL STICKER

POSITIONTUB STOP EXTRUSION

(ALUM0038-10)

FRONT RAIL

3

1

LOOSELY FIT(4) RETAINED CABIN GUARD BOLTS

RETAINED CABINGUARD BOLT

FITLH/RH RE-INFORCEMENT BRACKETS(CNPY0027PC-LH & CNPY0027PC-RH)

M8x25HEX BOLT

M8x25HEX BOLT

M8 SPRINGWASHER

M8 SPRINGWASHER

M8 FLATWASHER

M8 FLATWASHER

M8 FLATWASHER

M8 HEX NUT

TIGHTEN ALL TEN (10) BOLTS TO TORQUE 9Nm

3

4

5

6

7

LOWER HOLEIN SIDE PANEL

UPPER HOLEIN SIDE PANEL

1

CROSS SECTION THROUGH FRONTRAIL & RE-INFORCEMENT BRKT

FRONTRAIL

TUB STOPEXTRUSION

RE-INFORCEMENTBRACKET

TAPE

5

2

16/01/14Page 11 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Diagram: 20 - FIT RAIL EXTRUSION SPACER

20. Remove the liner film from the double sidedtape applied to the front tub spacer.Fit rail extrusion spacer(ALUM0038-9) to thefront rail over the tape aligning thepreviously marked centre lines. Apply firmpressure rearward and down on the fronttub spacer extrusion along the length toensure maximum adhesion of the foamtape. Clean any excess silicon off usingisopropyl alcohol.IMPORTANT: There must be NO siliconresidue left on the top of the side bedrail faces, or the bed rail foam tape willnot adhere correctly and water leakswill occur. Ensure no silicon is squeezedup by the fitting of the front tub spacerextrusion, if it is clean it off with IPA ona rag heavily loaded. (ref. diagram20).

CROSS SECTION THROUGH FRONT RAIL

TUBSPACER

SILICON

FRONT RAIL

TUB STOPTAPE

APPLYFIRM PRESSURE TO

ADHERE TAPE

REMOVETAPE LINER

1

FITFRONT TUB SPACER EXTRUSION

2

3

NOT SUPPLIED

FRONT TUB SPACER EXTRUSION

Diagram: 19 - APPLY SILICON TO THE TUB SPACER

19. Using a non permanent marker, measureand mark a line at the centre of the tubspacer (ALUM0038-9) and the centre ofthe front tub stop extrusion (ALUM0038-10)as shown. Apply a 10mm bead of non-acetic silicon(neutral cure), (not supplied) to the tubspacer on the short face between thetwo (2) grooves as shown.(ref. diagram19).

APPLY10mm BEAD OF SILICON

1 2 MEASURE & MARKCENTRE LINE OF TUB SPACER

MEASURE & MARKCENTRE LINE OF FRONT TUB STOP

= =

Diagram: 18 - “ST” - FIT TUB STOP

18. For “ST” vehicle’s onlyAlong the inside front face of the front railremove and discard the eight (8) plastic caps.Position the front tub stop extrusion(ALUM0038-10) on the front tub rail andsecure loosely using six (6) M8x25 hex bolts,M8 spring washers and M8 flat washersthrough the six (6) middle slots.Fit two (2) M8x25 hex bolts, M8 springwashers four (4) M8 flat washers and two (2)M8 hex nuts through the outboard slots asshown. Centre front tub stop extrusion to tub, andalign the top face of the front tub stopextrusion to the top of the front tub rail andtighten all eight (8) bolts to Torque 9Nm.(ref. diagram18).

CROSS SECTION THROUGH FRONT RAIL

FRONT RAIL

TUB STOPTAPE

9Nm

15mm

15mm

TIGHTEN ALL EIGHT (8) BOLTS TO TORQUE 9Nm5

POSITIONTUB STOP EXTRUSION

(ALUM0038-10)

2

3 3 3 3

3

3

34

4

4

4

M8x25HEX BOLT

M8 SPRINGWASHER

M8 FLATWASHER

M8 FLATWASHER

M8 HEX NUT

REMOVE & DISCARD(8) PLASTIC CAPS

1

16/01/14Page 12 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Diagram: 22 - INSTALL WATER SEALING TAPE

22. Apply EPDM foam tape (TAPE0386) fromhardware kit to the bed rails and spacer.Trim end of tape at 45° (20mm x 20mm) toalign with marks on the tub rail as shown.IMPORTANT: DO NOT CUT FOAM TAPE!Trim one end of the foam tape square.Starting from one side at the rear corner,position the tape end 30mm rearward ofthe tailgate stop and 5mm outboard ofthe inside edge and continue thisposition all the way along the side rail inone continuous length. Position tape25mm from the front edge of the fronttub spacer and apply tape down the otherside rail 5mm outboard of the inside edgeto the end of the side rail.IMPORTANT: As the tape bends aroundthe corners ensure the tape sits flat andDOES NOT pucker.Trim off excess square, 30mm rearwardof the tailgate stop 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. diagram22).Tape MUST be fully adhered to tub railsand spacer and sit flat in one continuouslength to prevent water entering thecanopy.

1

Diagram: 21 - VEHICLE SURFACE PREPARATION

21. Using alcohol wipes provided clean alltop rail areas of the tub and wipe awayresidue with a dry clean cloth. If heavycleaning is required use Iso-Propylalcohol and wipe away residue with adry clean clothUsing priming stick (MISC1365) prime toprails of the tub where EPDM foam tapewill be applied in (step 22). Please do notprime too far over the sides of the toprails, read (step 22) to understand wherethe foam tape is to be positioned anduse this as a guide for priming the area.Follow the instructions on the primingstick for optimum results.(ref. diagram21).

NOT SUPPLIED

APPLYEPDM FOAM TAPEAROUND BED RAIL

TOP VIEW OFVEHICLE TUB

CA

BIN

OF

VEH

ICLE

TRIM SQUARE

POSITIONEPDM FOAM TAPE

5mm OUTBOARD OF THEINSIDE EDGE ALONG

THE SIDE RAILS

POSITIONEPDM FOAM TAPE

25mm FROM THE FRONTEDGE OF THE FRONT

TUB SPACER EXTRUSION

ALONGSIDE RAILS

ALONGSIDE RAILS

FOAM TAPE MUST NOTPUCKER AROUND CORNERS

TRIM EXCESS SQUARE 30mm REARWARDOF TAILGATE STOP

ALONGFRONT RAIL

WITH SPACER

5mm 25mm

5mm

TAILGATE OFVEHICLE

30mm

30mm

2

16/01/14Page 13 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Diagram: 23 - APPLY SILICON

23. 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, ensure all gaps are silicon sealedproperly. 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. (ref. diagram23).

Diagram: 25 - PREPARE CANOPY

Diagram: 24 - APPLY SILICON

24.

25.

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. Run a 10mm bead ofsilicon on top of the EPDM foam tape inthe centre, around the corners for a lengthof 70mm each way as shown. Repeatprocess for the other side of the vehicle.Also check from inside and outside of thefront corners near the top of the tub andsilicon seal gaps in the tub sheetmetal.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram24).Clean front of canopy including the frontwindow.Apply a length of masking tape to thefront tub spacer (ALUM0038-9) for alength of 20mm and leave a length that isaccessible over the edge of the vehicle toassist in removing when the canopy hasbeen aligned.Using a non-permanent marker, measureand mark lines rearward from the frontedge of the front tub spacer as shown.“RX” vehicle’s - 14mm“ST” vehicle’s - 10mm“ST-X” vehicle’s - 17mmRepeat process for the other side of thevehicle. (ref. diagram25).

NOT SUPPLIED

CLEANCANOPY FRONT

1

20mm

SHEETMETALSIDE RAIL

FRO

NT

TUB

SPA

CE

R

TOP VIEW OF TUB FRONT CORNERAPPLY

MASKINGTAPE

2

MARK LINES3

“ST”

10m

m

“ST-

X”

17m

m

“RX

”14

mm

APPLYNON ACETIC

SILICON(NEUTRAL CURE)

EPDM FOAMTAPE

DOWN AT LEAST THE DEPTHOF THE RETURN OF THE FRONT

TUB SPACER EXTRUSIONFROM THE TOP OF THE TUB

SILICON SEAL GAPS IN THE CORNER OF TUB AT TOP

FRONT TUBSPACER

VEHICLE CABIN NOTSHOWN FOR CLARITY

NOT SUPPLIED

EPDM FOAMTAPE

TOP VIEW FRONT LEFT TUB CORNER INTERNAL VIEW INSIDE THE TUBFRONT

TUB STOPEPDM

FOAM TAPE

FRONTTUB STOP

FRONTTUB SPACER

APPLYNON ACETIC SILICON

(NEUTRAL CURE)

1

APPLYNON ACETIC SILICON

(NEUTRAL CURE)

2

70mm

70mm

16/01/14Page 14 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

DO NOT SLIDE CANOPYON EPDM FOAM TAPE

AND SILICON

2 FITCANOPY TO

VEHICLE

1 TAPEWIRING HARNESS

TO RH SIDE WINDOW

3FEED

CANOPY HARNESSBETWEEN TUB AND

CABIN DOWN TOCHASSIS RAIL

HARNESS

Diagram: 28 - FIT CLEAR ABRASION TAPE TO TUB

Diagram: 27 - ALIGN CANOPY TO TUB

27.

28.

Align the canopy evenly on the tub.The canopy lower perimeter extrusion’sfront face, should align with lines markedpreviously on the masking tape applied tothe front tub spacer using a straight edge.“RX” vehicle’s - 14mm“ST” vehicle’s - 10mm“ST-X” vehicle’s - 17mmOpen rear door to check sidewaysalignment. Using a steel ruler position thecanopy so both canopy base side railsare even to the width of the vehicle tub.From inside the canopy, also check thefront holes in the front rail of the canopy align to the centre of the holes in the tubspacer extrusion.Remove masking tape from front tubspacer. (ref. diagram27).

Diagram: 26 - FIT CANOPY TO TUB

26. Two people (minimum) are required forthis step.First tape the wiring harness to the RHside window with masking tape.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 EPDMfoam tape and silicon, as this candamage the foam tape and spread thesilicon (break the water seal).Remove masking tape and feed canopyharness down between tub and cabin (righthand side of vehicle) so it is accessibleunder the vehicle on the outside of thechassis rail. (ref. diagram26).

EVEN BOTH SIDESAT THE END CAPS

CANOPY BASE RAIL

VIEW FROMREAR OF CAR

RX=14mm, ST=10mm, ST-X=17mmFROM FRONT TUB SPACER

TO VERTICAL RULER

RULER VERTICAL AT LINEMARKED IN STEP 24.

0mm

1020

3040

5060

7080

90

Fit six (6) abrasion resistant clear tape 50x30mm pieces (TAPE0011), to the vehicle tub rails directly under the square holes in the canopy base rails for the clamps as shown. (ref. diagram28).

FIT CLEAR ABRASIONRESISTANT TAPE

TO TUBRAILS HORIZONTALLY

DIRECTLYUNDER CLAMP HOLES

IN BASE RAILS

TUBCLEAR TAPE

SECTION VIEW

16/01/14Page 15 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

10mm

FIT / SECUREFRONT RAIL TUB STOP

TIGHTEN TOTORQUE 6Nm

1

3

FITBOLT AND WASHER

SECURENYLOC NUT

AND WASHER

WASHER

NYLOC NUT

BOLT

CANOPY BASERAIL AT FRONT

2

VEHICLEFRONT TUB

SHEET METAL

6Nm

10mm

Diagram: 31 - FIT / SECURE - FRONT TUB STOP RAIL

31. For “ST-X” vehicle’s only.Fit front rail tub stop extrusion(ALUM0038-10) to the under side of thecanopy front base rail and front tub spacer.Push extrusion up against the front of thetub and secure with four (4) M6 hex headbolts, eight (8) flat washers and four (4)nyloc nuts as shown.Tighten to Torque 6Nm. For “RX & ST” vehicle’s only.Secure previously installed front rail tubstop extrusion (ALUM0038-10) to thecanopy front base rail and front tub spacerusing four (4) M6 hex head bolts, eight (8)flat washers and four (4) nyloc nuts asshown.Tighten to Torque 6Nm. (ref. diagram31).

20. Fit two clamps (CNPY0007) to the rear holes in the canopy base rails both sides by fitting the top L clamp down through the hole in the rail and sliding the lower U clamp along the side rail over the clear abrasion tape.(ref. diagram 20)

Apply Loctite 243 to a minimumof 20mm along thread of the bolts.Torque to 8Nm.

DISASSEMBLE2 CLAMPS

FITTOP ‘L’ CLAMP

1

2

4

FIT & SLIDEBOTTOM

‘U’ CLAMP

APPLYLOCTITE 243 TO BOLTS,FIT BOLT & WASHERS

TORQUE TO 8Nm

3

8Nm

13mm

13mm

Diagram: 20 - FIT REAR CLAMPS

20mm

LOCTITE243

4

DISASSEMBLE4 CLAMPS

1

FITREMAINING CLAMPS

APPLYLOCTITE 243 TO BOLTS

2

3TIGHTEN

2 - REAR CLAMPSTORQUE TO 11Nm

4TIGHTEN

2 - FRONT CLAMPSTORQUE TO 11Nm

5TIGHTEN

2 - MIDDLE CLAMPSTORQUE TO 11Nm

11Nm

13mm

13mm

Fit the four remaining clamps. (ref. diagram 22).

NOTE: Re-tighten the front clamps first, middle clamps second and the rear clamp towards the door, third to torque 11Nm.

Diagram: 22 - FIT REMAINING CLAMPS AND TIGHTEN ALL

20mm

LOCTITE243

222.

Apply Loctite 243 to a minimumof 20mm along thread of the bolts.Torque to 8Nm.

16/01/14Page 16 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

CLEARABRASION

TAPE

TRIMEXCESS CLEARABRASION TAPE

4

REMOVEMASKING TAPE

CANOPY NOT SHOWN FOR CLARITY

6

SQUEEGEE OUTEXCESS SOLUTION

BUBBLES

5

2

25% ISOPROPYLALCOHOL

75% WATER

APPLYCLEAR

ABRASION TAPE

ALIGNBOTTOM EDGE

OF CLEAR ABRASIONTAPE WITH TOP EDGE

OF MASKING TAPE

3

CUTCLEAR ABRASION TAPE

INTO TWO EQUAL HALVES

1

200 200 200

194

2009797 200 200

BOTTOM GROOVEON FRONT RAIL TUB STOP

TOP GROOVEON FRONT RAIL TUB STOP

Ø5mmRust

Inhibitor

(x8)1 2 3 4

Diagram: 32 - SECURE FRONT TUB STOP RAIL

32.

Diagram: 34 - APPLY ABRASION TAPE

34. Unroll and cut abrasion tape (TAPE0611-1) into two equal halves. Using a solution of25% isopropyl alcohol and 75% water in aspray bottle (not supplied) thoroughly sprayalong the top of the tailgate.Remove liner from clear abrasion tape.Working from one end with a 5mm over-hang, place liner on the tailgate. Trimexcess tape leaving a 5mm overhang atplastic infill panel. When in position use asqueegee to push out any excess watersolution and bubbles. Using a sharp knifeor scissors trim tape to end of tailgate &infill panel.You may need to squeegee a few times.When finished the tape is virtuallyinvisible. Repeat for the other side.To ensure a good finish please take carean do not rush this step. Remove maskingtape. (ref. diagram34).

For “ST-X” vehicle’s onlyMark and drill eight (8) Ø5mm holes intothe front rail tub stop and tub rail usingdimension’s as shown.Rivets must secure to flat form on tub.Apply rust inhibitor (MISC2776) to alldrilled holes in the tub sheet metal.Secure with eight (8) stainless steel rivetsas shown. (ref. diagram32).

TAILGATE

REARDOOR SASH

MASKINGTAPE

REAR WINDOW

APPLYMASKING TAPETO TAILGATE

1

Diagram: 33 - APPLY MASKING TAPE

33. With the canopy rear door closed, applya length of masking tape either side of theplastic infill panel to the rear tailgate, levelwith the bottom edge of the canopy reardoor sash, when viewed from the rearhorizontal position as shown.This will assist in positioning the clearabrasion tape applied to the top of thetailgate in the next step.(ref. diagram33).

1

16/01/14Page 17 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

CHECKCANOPY LAMP

WORKS

Diagram: 37 - CHECK BRAKE LIGHTS AND CANOPY LIGHT

Diagram: 36 - CONNECT VEHICLE & CANOPY CONNECTORS

36.

37.

Feed the canopy harness down to thevehicle harness on the chassis rail.Connect the canopy harness connector tothe vehicle harness connector as shown.IMPORTANT: Wiring harnesses shouldbe positioned away from the exhaustsystem side. (ref. diagram36).

Two people are required to check thecanopy brake light is operational afterdepressing the brake pedal.Then open the rear window and checkthat the internal canopy lamp is operatingcorrectly when switched to the ’ON’position only.NOTE: An additional accessory can beordered from EGR to turn the light onin ‘DOOR’ position of the switch when thedoor is opened automatically.(ref. diagram37).

CHECKBRAKE LIGHTS

WORK

CONNECTCANOPY HARNESS TO VEHICLE HARNESS

1

CHASSIS RAIL

Diagram: 35 - (OPTIONAL) FIT TAILGATE SEALS

35. (OPTIONAL): Strongly Recommendedfor best results for rear door to tailgatewater sealing. Using alcohol wipe provided clean directlybelow the rear door clamp front seal andwipe away residue with a dry clean cloth.Using priming stick (MISC1365) prime areadirectly below the rear door clamp frontseal. Apply only a light amount both sides of tailgate in this area, and allow to dry. Apply bulb seal 70mm (MISC2600-1) totailgate. Position bulb seal so it's fingerseals against the underside of theclamp frame seal after the bulb on the clampframe seal as shown and position it in linewith the outer edge of the tailgate as shown.(ref. diagram35).

BULBSEAL

CLAMPFRAMESEAL

TAILGATE

SIDETUBRAIL

ALCOHOLWIPE &PRIME

SHADEDAREA

1 2

TAILGATE

1

2

BU

LB S

EA

L FI

NG

ER

UN

DE

R C

LAM

P S

EA

L&

AG

AIN

ST

FIN

GE

R

CANOPYCROSS SECTIONOF SEAL

FIT BULB SEAL3

16/01/14Page 18 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

FITCABLE TIE

Diagram: 39 - SECURE CANOPY HARNESS

39. Fit one (1) short cable tie through theadhesive tie pad previously fitted to thefront of the tub and secure the canopywiring harness as shown. Trim excess tiewith side cutters. (ref. diagram39).

CANOPY

CABIN

TUB

Diagram: 38 - FIT ADHESIVE TIE PAD

38. Using alcohol wipe provided in the kit,clean the driver’s side, front face of thefront tub panel as shown, and wipeaway residue with a dry clean cloth.Remove tape liner from adhesive tie padand position on the front tub panel in areapreviously cleaned as shown.Apply pressure to ensure maximumadhesion. (ref. diagram38).

CANOPY

CABIN

TUBSPACER

TUB

1 FITADHESIVETIE PAD TOFRONT TUB

PANEL

2

TUBSPACER

PLACE FITTING INSTRUCTIONSIN THE CUSTOMERS LOG BOOK

Diagram: 40 - FINAL CLEANING

40. Clean canopy including all windowsand vehicle thoroughly .Place fitting instructions in theCustomers log book, and ensurepage 20 of these instructions arediscussed with the customer and acopy is given to the customer. (ref. diagram40).

16/01/14Page 19 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

LOOSEN BOLTS FOR ADJUSTMENT

LOOSENNUTS FOR ADJUSTMENT

SLIDE TO SIDEADJUSTMENT TO ALIGN

WITH REAR DOOR LATCH

1

1

2

9Nm

13mm

11Nm

13mm

13mm

13mm

Diagram: 41 - ADJUST STRIKER BRACKET

Diagram: 42 - ADJUST STRIKER

Diagram: 43 - 2nd STAGE LATCHING POSITION

41. Ensure rear door latch engages onto the striker hoop. Striker hoop cross-car direction can be adjusted by loosing 3 x M6 bolts and sliding striker bracket. Re-tighten bolts to 9Nm.(ref. diagram 41).

42. Door position forward / rearward can beadjusted by loosing 4 x M8 nuts on the threaded striker hoop. Readjust position as required. Re-tighten to 11Nm. (ref. diagram 42).

43. Ensure latch reaches 2nd stage position,as shown. (ref. diagram 43).

LATCH STRIKER ADJUSTMENT

LATCH

STRIKER

IMPORTANT: The latch system is a twostage system. Ensure that the rear door latches engage to the second stage when the rear door is closed.

16/01/14Page 20 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Diagram: 44 - PULL RODS ADJUSTMENT

44. Check rear door handle operation: This can be checked with the door open, manually depress latches and activate handle. Handle should activate latches at 2/3 of handle travel simultaneously for LHS and RHS. If required, adjust pull rods as shown: Spinning clockwise - shorten. Spinning anticlockwise - lengthen.(ref. diagram 44).

NOTE: If required latch position on the rear door can be adjusted side to side by removing latch cover and loosening 2 x M8 nuts holding latch in position. Re-tighting to 8Nm.

ADJUST LENGTHOF PULLRODS BY ROTATION

ANTI-CLOCKWISE = LENGTHEN

CLOCKWISE = SHORTEN

3

REMOVE INTERIORLOCK COVER

UNCLIP PULLRODSFROM RETAINER CLIPS

REPLACE INTERIORLOCK COVER

RE-CHECKLOCK

FUNCTION

4

CLIP PULLRODSINTO RETAINER CLIPS5

2

1

6

LATCH STRIKER ADJUSTMENT

16/01/14Page 21 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

Warranty Terms - EGR warrants that the ABS 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

Nissan Navara D40 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.

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

VEHICLE SERVICE BOOK.

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.• Do not fill volatile liquid containers while inside canopy such as fuel cans.• VEHICLES FITTED WITH A BED 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.

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) to canopy and rod (narrow end) to glass.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.Vaseline may be used on the rotary catches on the rear door.DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.Check canopy attachment clamps every 1000 Km.Clamp bolt recommended torque setting is (9 Nm or 6.64 lb/ft).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 or 3Mwindow channel dresser lubricant sparingly. DO NOT use CRC, WD40 or petroleum based lubricants on sliding windows.

16/01/14Page 22 of 22

CP0019dNISSAN NAVARA D40 - CANOPY

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, tub stop 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 on second stage latch (not just first latch) both sides and lower door sash seal, seals to tailgate, adjust strikers and /or door latch pull rods via access to centre door handle by removing internal door handle cover

7. Clamps 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. If not locking remove interior cover on rear door handle and adjust the pull rods by winding them in/out and test the door again, replace cover.

10. Operation of Brake Light

11. Operation of interior light

12. Water Tested for leaks

13. Clean up of work area

14. Comment

Record Canopy Serial Number: Checked By:

Vehicle Type: RX 4x2 RX 4x4 ST 4x4 ST-X 4x4

Vehicle received and Checked by Dealer Staff:

Fitted By:

INSTALLATION CHECKLIST

(located on inside LH rear pillar of canopy shell)