retro fit remote locking 1pc/3pc tonneau cover … · 2009. 2. 25. · retro fit remote locking...

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

Holden VE Ute 2007Part Number: EGR-RETROLOCK

RETRO FIT REMOTE LOCKING1PC/3PC TONNEAU COVER

INSTALLATION INSTRUCTIONS

Item

1

2

3

4

5

6

7

8

9

1

1

1

1

1

15

15

2

1

1

1

1

1

1

4

1

1

1

Vehicle Wiring Harness

Tonneau Wiring Harness

Interior Light

Rubber Gasket

Actuator Assembly

P-Clips

Short Self-Tapping Screws

Long Self-Tapping Screws

Phillips Head Screw

Component Name Qty Item

10

11

12

13

14

15

16

17

18

Flat Washer

Star Washer

Lock Cam with Ball Stud

Plastic Spacer

Module

Rivets

Gas Strut

Pullrod Clip

Bedrail Foam Tape

Component Name Qty

LIST OF PARTS

Drill with Ø3, Ø6, Ø12 & Ø14mm Drill Bits

Masking Tape

Phillips Head Screwdriver

Rivet Gun

Flat Head Screwdriver

Tape Measure

Torx Head Screwdriver and Bits

Spanners & Sockets

File

Scissors

RECOMMENDED TOOL LIST

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Clean Tonneau Cover with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

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.• Do not cycle remote key fob continuously or the actuator for operation of the remote locking system will burn out.

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RETRO FIT REMOTE LOCKING 1PC/3PC TONNEAU COVER

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1 2 3 4

5 6 7 8

9 10 11 12

13

17

14

18

15 16

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1. Open Tonneau Cover and detach gas struts by inserting a small screw driver and adjusting the spring clip on the 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

BALL STRUT SCREW

GAS STRUT

1

32

GAS STRUT

3

HINGEPIN

RIGHT HAND SHOWN2RIGHT HAND SHOWN1

HINGEPIN

3. Remove and retain the ball stud screws and the gas strut brackets from the side rail as shown. Outline the position of the lock striker bracket, drill out the rivets holding it in place and then remove it. Retain all hardware. See Dia #3. IMPORTANT: Be extremely careful when removing the lock striker bracket to not lose the plastic spacers by letting them fall off the thread and into the side panel of the vehicle.

Diagram #3

Ø5mm

PLASTICSPACERS

REMOVEBALL STUDSCREWS

RIGHT HAND SHOWNRIGHT HAND SHOWN

1

DRILL OUTRIVETS

4

32

OUTLINELOCK STRIKER

POSITION

REMOVELOCK STRIKER

BRACKETS

5

REMOVEGAS STRUTBRACKETS

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IMPORTANT: If vehicle is fitted with a Sports Bar proceed to Diagram #5 below.Otherwise, proceed to Diagram #9.

4. Remove and retain the three (3) tie-down brackets on the right hand of the bed using a torx-head screwdriver as shown. Open the vehicle’s tailgate and remove and retain the two (2) push rivets and peel back the rubber tailgate seal as far as the base of the tailgate as shown. See Dia #4.

Diagram #4

TORX HEADSCREWS

TIE-DOWNBRACKETS

211

1

2

3PUSH

RIVETS

TAILGATESEAL

RIGHT HAND VIEW INSIDEVEHICLE TUB

5. Remove and retain the jacking brackets from the side rail as shown. Remove and retain the hardware that attaches the Sports Bar to the corner pieces as shown. See Dia #5.

Diagram #5

6. Remove and retain all Sports Bar hardware. See Dia #6.

Diagram #6

RIGHT HAND SHOWN RIGHT HAND SHOWN1 2

RIGHT HANDFRONT LEG

RIGHT HANDREAR LEG

REMOVEHARDWARE

REMOVEHARDWARE

RIGHT HAND SHOWN UNDERSIDEOF CORNER

PIECE

REMOVEHARDWARE

SPORTSBAR

CORNERPIECE

REMOVEJACKINGBRACKET

1 RIGHT HAND SHOWN2

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IMPORTANT: If your vehicle was fitted with a Sports Bar, skip Diagram #9 and proceed to Diagram #10.

9. Lift and pull the bedliner as shown to gain access to the wiring located in the side panel of the vehicle. Disconnect the vehicle’s stop light wiring connectors located behind the bedliner. See Dia #9. NOTE: This connector is located above the wheel arch towards the rear of the vehicle.

Diagram #9

BEDLINER

STOP LIGHTWIRING PLUG

BEDLINER

TAILGATESEAL

1 2

DISCONNECT

7. Lift and pull the bedliner as shown to gain access to the wiring located in the side panel of the vehicle. Disconnect the Sports Bar LED wiring adapter from the vehicle stop light wiring connectors located behind the bedliner. The Sports Bar LED wiring adapter is no longer needed and can be discarded. Also disconnect the Sports Bar LED wiring harness from the Sports Bar LED wiring adapter as shown. See Dia #7.

Diagram #7

BEDLINER

TAILGATESEAL

1 2

SPORTS BAR LEDWIRING ADAPTER

VEHICLE STOP LIGHTWIRING CONNECTORS

SPORTS BAR LEDWIRING HARNESS

DISCONNECT

DO NOT REMOVE THE CORNERPIECES FROM THE VEHICLE

SPORTS BAR

DISCONNECT

DISCONNECT

8. Remove the Sports Bar from the vehicle, ensuring the Sports Bar LED wiring harness is carefully guided out from behind the bedliner and is not damaged. Do not remove the corner pieces. See Dia #8. IMPORTANT: Now proceed to Diagram #10 (Skip Diagram #9).

Diagram #8

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10. Insert the vehicle wiring harness between the two stop light wiring plugs as shown. See Dia #10.

Diagram #10

STOP LIGHTWIRING CONNECTOR

STOP LIGHTWIRING CONNECTOR

VEHICLE WIRINGHARNESS

CONNECT

CONNECT

11. Find the white 2-way connectors on the vehicle (directly behind the wheel arch) and unclip them from the vehicle as shown. Disconnect the white 2-way connectors. Connect the white 2-way connectors on the wiring harness to the white 2-way connectors from the vehicle as shown. Finally clip the white 2-way connector back onto the vehicle. See Dia #11.

Diagram #11

2-WAYCONNECTORS

(VEHICLE)

EARTH WIRETERMINAL(VEHICLE)

EARTH WIRETERMINAL(WIRING

HARNESS)

BOLT

BOLT

RE-ATTACHBOLT

UNCLIP FROMMOUNT DISCONNECT

12. Find the earth wire terminal behind the bedliner near the vehicle’s tailgate and remove the bolt holding the terminal together as shown. Locate the earth wire from the wiring harness and locate it over the hole that the bolt was just removed from. While holding everything in place, re-attach the bolt to the earth wire terminal on the vehicle as shown. See Dia #12.

Diagram #12

1

1

2-WAYCONNECTORS

(VEHICLE)

2-WAYCONNECTORS

(VEHICLE)

2-WAYCONNECTORS

(WIRING HARNESS)

CONNECT

CONNECT2 3

3

REMOVEBOLT

2

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13. Find the middle tie down bracket hole and push the spade terminal from the vehicle wiring harness through it as shown.See Dia #13.

Diagram #13

MIDDLE TIE DOWN BRACKET HOLE

PUSH SPADE TERMINAL THROUGHHOLE IN BEDLINER

SPADE TERMINAL(VEHICLE WIRING HARNESS)

4-WAY GREYCONNECTOR

VEHICLE WIRING HARNESS(BEHIND BEDLINER)

14. Run the grey 4-way connector from the vehicle wiring harness all the way to the front of the tub behind the bedliner as shown. At the front of the tub, pull the grey 4-way connector 200mm out from behind the bedliner as shown. See Dia #14.

Diagram #14

4-WAY GREYCONNECTOR

VEHICLE WIRING HARNESS

200mm

15. Fit the Sports Bar to the vehicle as shown. Tuck the Sports Bar LED wiring harness up under the side rail and behind the bedliner as shown. See Dia #15.

Diagram #15

IMPORTANT: If vehicle has a Sports Bar proceed to Diagram #15 below.Otherwise, proceed to Diagram #21.

1


BEDLINER

BULB SEAL

SPORTS BARRIGHT HAND LEG

CLAMPINGPLATE

RIGHT HAND ONLY2

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17. Attach the jacking brackets to the side rail using the retained hex head self-tapping screws as shown. Tighten to torque 3Nm. Fasten the corner pieces to the Sports Bar using the retained M6x30mm screws, M6 spring washers, and M6 flat washers as shown. See Dia #17.

Diagram #17

RIGHT HAND SHOWN UNDERSIDEOF CORNER

PIECESPORTS

BARJACKINGBRACKET

1 RIGHT HAND SHOWN2

TORQUE3Nm

HEX HEAD SELF-TAPPING SCREWS

M6x30mmSCREWS

M6 FLATWASHER

M6 SPRINGWASHER

16. Feed the LED wiring loom along the inside of the side panel and attach the Sports Bar LED wiring harness to the vehicle wiring harness as shown. Ensure the male wiring connector is orientated correctly when attaching. See Dia #16.

Diagram #16

WHITE LEDCONNECTOR

VEHICLE WIRINGHARNESS

SPORTSBAR LEDWIRING

HARNESS

WHITE LEDCONNECTOR

(VEHICLE WIRING HARNESS)


18. Attach the Sports Bar front legs to the clamping plates and side rails using the retained 12Gx1½” self tapping screws, M6 spring washers and washer plates as shown. Do not tighten yet. Repeat process for the Sports Bar rear legs. See Dia #18.

Diagram #18

CLAMPINGPLATE

M6 SPRINGWASHER

12Gx1½” SELFTAPPINGSCREW

WASHERPLATE

CLAMPINGPLATE

RIGHT HAND SHOWN RIGHT HAND SHOWN

RIGHT HANDFRONT LEG

RIGHT HANDREAR LEG

M6 SPRINGWASHER

12Gx1½” SELFTAPPINGSCREW

1 2

WASHERPLATE

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19. Attach the Sports Bar front legs to the clamping plates using the retained M6x20mm screws and M6 spring washers as shown. Do not tighten yet. Repeat process for the Sports Bar rear legs. See Dia #19.

Diagram #19

CLAMPINGPLATE

M6 SPRINGWASHER

M6x20 SCREW

M6x20 SCREW

WASHERPLATE

CLAMPINGPLATE


M6 SPRINGWASHER

WASHERPLATE

1 2

RIGHT HANDFRONT LEG

RIGHT HANDREAR LEG

20. Tighten all the screws on the Sports Bar right hand leg in the order A - B - C - D - E - F. Tighten A, B, D & E to torque 12Nm. Tighten C & F to torque 10Nm. Repeat process for the Sports Bar left hand leg. Visually check that all scews are home and all spring washers are compressed. See Dia #20.

Diagram #20

TIGHTENTORQUE 12Nm

RIGHT HAND SHOWN RIGHT HAND SHOWN1

D EF

TIGHTENTORQUE 12Nm

TIGHTENTORQUE 10Nm

TIGHTENTORQUE 12Nm

CA B

2

RIGHT HANDFRONT LEG

RIGHT HANDREAR LEG

TIGHTENTORQUE 10Nm

TIGHTENTORQUE 12Nm

21. Re-attach the bedliner by lifting it back into position, re-installing the tie-down brackets, the push rivets and the tailgate seal as shown. See Dia #21.

Diagram #21

TORX HEADSCREWS

TIE-DOWNBRACKETS

211

1

2

3PUSH

RIVETS

TAILGATESEAL

RIGHT HAND VIEW INSIDEVEHICLE TUB

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22. Attach gas strut brackets to the side rail using retained hardware. Attach the ball stud screws to the gas strut brackets as shown. Tighten to torque 4Nm. Align the lock striker bracket with the previously drawn outline and attach it to the side rail panel using the retained 12g self-tapping screws, flat washers (14mm x 5.5mm) and plastic spacers as shown. DO NOT OVERTIGHTEN! Finally, attach the rivets to the lock striker bracket as shown. See Dia #22. NOTE: Plastic spacers fit inside the side rail panel between the thread nut and lock striker bracket.

Diagram #22

SPADE TERMINALCONNECTS TO GAS STRUT

4-WAY MALE CONNECTORCONNECTS TO VEHICLE

WIRING HARNESS

6-WAY MALE CONNECTORCONNECTS TO MODULE

2-WAY MALE CONNECTORCONNECTS TO ACTUATOR

2-WAY MALE CONNECTORCONNECTS TO LED

23. Lay the Tonneau Cover upside down on a sheet or mat to prevent scratching. Spread the Tonneau wiring harness out on the Tonneau Cover as shown, taking note of the different connectors and their correct positions. See Dia #23.

Diagram #23

24. Once the Tonneau wiring harness is in position, apply masking tape to the area where the wiring intersects to hold the harness in place. See Dia #24.

Diagram #24

APPLY MASKING TAPE

ATTACHBALL STUDSCREWS

TORQUE 4Nm


2

13

ATTACH 12gx1½”SELF-TAPPING

SCREWS

4ATTACHRIVETS 2

FLAT WASHERS(14mm x 5.5mm)

LOCK STRIKERBRACKET

PLASTICSPACERS

DO NOT OVER-TIGHTEN

ALIGNBRACKET

WITHOUTLINE

ATTACHGAS STRUTBRACKETS

TORQUE 3Nm

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Ø12mmØ3mm

SPADETERMINAL

25. Drill Ø3mm pilot holes followed by Ø12mm holes in the Tonneau Cover at the correct locations as shown. Thread the Tonneau wiring harness (spade terminal end) through the holes as shown. See Dia #25.

Diagram #25

26. Attach fourteen (14) p-clips to the Tonneau wiring harness at the correct locations as shown, with the hole located at the top. Attach one (1) p-clips to the Tonneau wiring harness at the correct location as shown, with the hole located underneath. See Dia #26.

Diagram #26

DRILL Ø3MMPILOT HOLES

FOLLOWED BYØ12MM HOLES

THREAD TONNEAUWIRING HARNESS

THROUGHDRILLED HOLES

1

2

27. While holding the p-clips in position, drill Ø3mm holes in the Tonneau Cover through the hole in each p-clip as shown. Fasten the p-clips to the Tonneau Cover using the self-tapping screws provided. See Dia #27. IMPORTANT: Before drilling the holes, ensure p-clips are positioned in such a way that the Tonneau wiring harness will remain firmly attached to Tonneau Cover. Also ensure the p-clip closest to the front of the Tonneau Cover is upside down and positioned at an angle as shown.

Diagram #27

P-CLIPS

P-CLIP

TONNEAU WIRING HARNESS


x14

x1

1

2

4-WAYCONNECTOR

TONNEAU WIRINGHARNESS

DRILL Ø3MMHOLES

Ø3mm

POSITIONP-CLIPS

1

2

3 ATTACH SELF-TAPPING SCREWS

x3

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29. While holding the p-clips in position, drill Ø3mm holes in the Tonneau Cover through the hole in each p-clip as shown. Fasten the p-clips to the Tonneau Cover using the self-tapping screws provided. See Dia #29. IMPORTANT: Before drilling the holes, ensure p-clips are positioned in such a way that the Tonneau wiring harness will remain firmly attached to Tonneau Cover.

Diagram #29


x5

Ø3mm


Diagram #28


x2

Ø3mm

POSITIONP-CLIPS

1

POSITIONP-CLIPS

1

DRILL Ø3MMHOLES

2

DRILL Ø3MMHOLES

2



TONNEAUWIRING

HARNESS

SPADETERMINAL


Diagram #30

Ø3mm

POSITIONP-CLIPS

1

DRILL Ø3MMHOLES

2


x2

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Diagram #31

Ø3mm

Ø3mm


x2POSITIONP-CLIPS

1

DRILL Ø3MMHOLES

2


2-WAYCONNECTOR

32. Drill a Ø3mm followed by a Ø14mm hole in the Tonneau Cover at the corect location as shown. See Dia #32.

Diagram #32

Ø14mmØ3mm DRILL Ø3MM

PILOT HOLEFOLLOWED BYØ14MM HOLE

WIRINGHARNESS

2-WAYCONNECTOR

33. Thread the Tonneau wiring harness though the previously drilled hole as shown. While holding the final p-clip in position, drill Ø3mm hole in the Tonneau Cover through the hole in the p-clip as shown. Fasten the p-clip to the Tonneau Cover using the self-tapping screw provided. See Dia #33.

Diagram #33

2-WAY CONNECTOR THREAD WIRINGHARNESS

THROUGH HOLE

1

POSITIONP-CLIP

2

DRILL Ø3MMHOLE

3


x1

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Ø6mmØ3mm

34. Remove the inspection cover to gain access to the Tonneau’s locking mechanism. Remove and discard the screw and washers holding the lock cam in place as shown. Do not remove the lock cam. Fit the ball stud lock cam, plastic spacer, flat washer and star washer to the locking mechanism using the phillips head screw provided. TIGHTEN TO TORQUE 4Nm. See Dia #34. IMPORTANT: Ensure both lock cams are aligned with eachother and with the locking mechanism as shown.

Diagram #34

36. Cut out drill template #1 and position it on the Tonneau Cover over the inspection hole. Once in position, use a centre punch to lightly mark the hole locations onto the Tonneau Cover. Remove the template and drill Ø3mm pilot holes followed by Ø6mm holes at the locations marked. See Dia #36.

Diagram #36

DRILLTEMPLATE #1

DRILL Ø3MM PILOT HOLESTHEN Ø6MM HOLES

35. Ensure the pullrod and pullrod clip on the DRIVER’S SIDE of the locking mechanism are orientated correctly as shown. If they are not orientated correctly, remove the pullrod and pullrod clip and re-attach them correctly. You may need to replace the pullrod clip with a new one provided with the hardware kit. See Dia #35.

Diagram #35

STAR WASHER

TORQUE 4Nm

FLAT WASHER

PLASTIC SPACER

LOCK CAMWITH BALL STUD

ORIGINALLOCK CAM

PHILLIPS HEADSCREW

LOCK CAM

1 2REMOVE SCREWAND WASHERSAND DISCARD

IMPORTANT:THE CAM, WASHERS& SCREW MUST BE

FITTED IN THE ORDER SHOWN

ENSURE THE PULLROD AND PULLRODCLIP ON THE DRIVER’S SIDE OF THE

LOCKING MECHANISM AREORIENTATED CORRECTLY

PULLROD CLIP

PULLROD

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37. Connect the 2-way connector from the Tonneau wiring harness with the actuator as shown. See Dia #37.

Diagram #37

38. Position the actuator inside the Tonneau Cover and attach the long self-tapping screws as shown. Finally, clip the pullrod from the actuator onto the lock cam with ball stud as shown. See Dia #38. NOTE: Ensure the joining element and pull rod clip are attached to the actuator. If they aren’t, clip them into place as shown. Also ensure that all the wiring is moved out of the way and cannot interfere with the locking mechnism. Replace any bedrail foam tape that was damaged with the foam tape provided in the hardware kit.

Diagram #38

1

2

POSITION ACTUATORINSIDE TONNEAU

BEDRAILFOAM TAPE

JOININGELEMENT

PULLROD CLIP

ATTACHSELF- TAPPING

SCREWS

3

39. Attach the module to the 6-way male connector on the Tonneau wiring harness. Remove the protective backing from the module and adhere it the Tonneau Cover as shown. See Dia #39.

Diagram #39


ACTUATOR

12

ATTACH MODULETO CONNECTOR

AND THEN TO THETONNEAU COVER

WIRING HARNESSCONNECTOR

LOCKING MECHANISM

MODULE

CLIP PULLRODTO BALL STUD

LOCK CAM

ENSURE JOININGELEMENT ANDPULLROD CLIPARE ATTACHEDTO ACTUATOR

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40. Cut out drill template #2 and position it on the Tonneau Cover as shown. Once the template is taped in place, use a file to widen the edges of the hole in the Tonneau Cover to meet the edges of the hole in the template as shown. If the holes are already the same size, proceed to the next Diagram. See Dia #40.

Diagram #40

41. Use a centre punch to lightly mark the hole location in the Tonneau Cover as indicated by the drill template. Remove the template and drill a Ø3mm pilot hole followed by a Ø12mm hole at the marked location. Thread the 2-way connector from the Tonneau wiring harness through the drilled hole. See Dia #41.

Diagram #41

Ø12mmØ3mm

DRILLTEMPLATE #2

42. While holding the spring-loaded catches down, fit the rubber gasket to the interior light as shown. Connect the 2-way male connector from the Tonneau wiring harness to the female connector from the interior light as shown. While holding the spring-loaded catches down, insert the interior light into the Tonneau Cover. The spring-loaded catches will spring back once the light is installed and will hold it in place. See Dia #42. IMPORTANT: Ensure that all the wiring for the interior light is contained inside the Tonneau Cover before installing the interior light.

Diagram #42

21 3 4

2-WAYCONNECTOR

INTERIORLIGHT

INTERIORLIGHT

SPRING-LOADEDCATCHES

INTERIORLIGHT

WIRING HARNESS

HOLD SPRING-LOADEDCATCHES DOWN

SPRING-LOADEDCATCHES

RUBBERGASKET

1 2

THREAD CONNECTORTHROUGH DRILLED HOLE

2-WAYCONNECTOR

WIRINGHARNESS

DRILL A Ø3MM PILOTHOLE FOLLOWEDBY A Ø12MM HOLE

DRILL TEMPLATE #2

MASKING TAPE

FILE EDGES OF HOLE UP TO THE

EDGES OFTHE TEMPLATE

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43. Open vehicle’s tailgate. Fit Tonneau Cover and secure hinges with hinge pins as shown. See Dia #43.

Diagram #43

“CLICK”

RIGHT HAND SHOWN4

HINGEPIN

HINGEPIN

RIGHT HAND SHOWN32

1

44. Remove and discard the driver’s side gas strut and replace it with the new gas strut supplied in the hardware kit. Attach the gas struts by clipping them into place as shown. ENSURE THE NARROW END OF THE GAS STRUT MOUNTS TO THE VEHICLE. Connect the wiring harness to the terminals on the driver’s side gas strut as shown. See Dia #44. NOTE: Attach gas strut with terminals to the driver’s side of the vehicle.

Diagram #44

GAS STRUT DRIVER’S SIDE ONLYWIDEEND

REPLACE THISGAS STRUT WITHTHE NEW STRUT

SUPPLIED INHARDWARE KIT

NARROWEND

1 2

GAS STRUTBOTTOM

GASSTRUT TOP

45. Adjust jacking bolts until corner pieces are level with the main surface of the Tonneau Cover. Once in the correct position, lock the M8 nuts into position against the bracket using a spanner. Repeat for other side of vehicle. See Dia #45.

Diagram #45

RIGHT HAND SHOWN

CORNERPIECE

TONNEAUCOVER

1 2

M8NUTS

M8 HEXHEAD BOLT

CORNERPIECE

IMPORTANT: If vehicle has a Sports Bar proceed to Diagram #45 below.Otherwise, proceed to Diagram #46.

TONEAUWIRING

HARNESS

VEHICLEWIRING

HARNESS

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48. Manually lock and unlock the Tonneau Cover using the key supplied. Check operation of the central unlocking mechanism by pressing the lock and unlock on your vehicle’s key. Review operation through the inspection cover. Test operation of lock mechanism by pressing Tonneau’s push button after you have pressed lock on the vehicle’s key, and then again after you have pressed unlock on the vehicle’s key. Finally, replace the inspection cover. See Dia #48.

Diagram #48

TONNEAULOCKED

TONNEAUUNLOCKED

GENTLYCLOSE

TONNEAULOOSENSCREW

OPENTONNEAU

COVER

47. Join the two 4-way connectors located at the front of the tub as shown. Push the terminals behind the bedliner after they are attached. See Dia #47.

Diagram #47

46. Loosen the screw found on the terminal housing on the driver’s side gas strut, until it can move up and down the strut freely. With the tailgate open, gently close the Tonneau Cover. Inspect the driver’s side gas strut and ensure the terminal housing has come into contact with the gas strut’s cylinder as shown. Finally, open the Tonneau Cover and tighten the screw on the terminal housing as shown. See Dia #46.

Diagram #46

1 2 43 5

ENSURE CONTACTHAS BEEN MADE

GASSTRUT

CYLINDER

TIGHTENSCREW

4-WAY MALECONNECTOR

(VEHICLE WIRING HARNESS)

4-WAY FEMALECONNECTOR

(TONNEAU WIRINGHARNESS)

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49. Open and close the Tonneau Cover with the tailgate open to check whether or not the Tonneau Cover interior light is functioning correctly. Ensure that the light turns on when the Tonneau is open and turns off when the Tonneau is closed. If the light DOES NOT work, check adjustment of the gas strut switch (refer to Diagram #46). See Dia #49.

Diagram #49

TONNEAU COVERINTERIOR LIGHT

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REMOVAL OF TONNEAU COVER

1. Open Tonneau Cover, pull the 4-way connectors out from behind the bedliner and disconnect them. Disconnect the wiring harness from the terminals on the driver’s side gas strut. Detach gas struts by inserting a small screw driver and adjusting the spring clip on the 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 remove the Tonneau Cover as shown. See Dia #2.

Diagram #2

BALL STRUT SCREW

GASSTRUT

4

5

3

1 GAS STRUT

HINGEPIN

RIGHT HAND SHOWN2 3RIGHT HAND SHOWN1

HINGEPIN

DRIVER’S SIDE ONLY2

GAS STRUTBOTTOM

GASSTRUT TOP

TONEAUWIRING

HARNESS

VEHICLEWIRING

HARNESS

4-WAYCONNECTORS

UNDERSIDE OFTONNEAU COVER

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REPLACEMENT OF TONNEAU COVER

1. Fit Tonneau Cover and secure hinges with hinge pins as shown. See Dia #1.

Diagram #1

2. Attach gas struts by clipping into place. ENSURE THE NARROW END OF THE GAS STRUT MOUNTS TO THE VEHICLE. Connect the wiring harness to the terminals on the driver’s side gas strut as shown. Join the two 4-way connectors located at the front of the tub and push them behind the bedliner. See Dia #2. NOTE: Refer to Diagram #46: Ensure the gas strut switch works correctly and adjust if necessary.

Diagram #2

“CLICK”

RIGHT HAND SHOWN3

3

HINGEPIN

4-WAYCONNECTORS

UNDERSIDE OFTONNEAU COVER

RIGHT HAND SHOWN21

HINGEPIN

GAS STRUTDRIVER’S SIDE ONLYWIDE

END

NARROWEND

BALL STRUTSCREW

1 2

GAS STRUTBOTTOM

GASSTRUT TOP

TONEAUWIRING

HARNESS

VEHICLEWIRING

HARNESS

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DRILL TEMPLATE #1

CUTAWAY

DRILL Ø3MM PILOT HOLESTHEN Ø6MM HOLES

PUSH THIS EDGEUNDER RUBBER SEAL

DRILL TEMPLATE #1

REAR OF TONNEAU

ALIGN WITHINSPECTION HOLE

DRILL Ø3MM THEN Ø12MM

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DRILL TEMPLATE #2

CUT AWAY

REAR OFTONNEAU

ALIGN CENTRE OF TEMPLATEWITH CENTRE OF HOLE

IN TONNEAU COVER

DR

ILL

TEM

PLATE #2 INCREASE HO

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retro fit remote locking 1pc/3pc tonneau cover … · 2009. 2. 25. · retro fit remote locking...

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