tc0143b 3pc tonneau cover with remote locking … falcon fg 3p... · 2014-03-24 · tc0143b page 6...

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

Ford Falcon Ute 08

3PC TONNEAU COVERWITH REMOTE LOCKING

INSTALLATION INSTRUCTIONS

Item

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

1

1

1

1

4

4

6

4

8

4

1

2

2

2

4

4

4

2

1

1

2

2

Tonneau Cover

Header Rail Assembly

Corner Piece LHS

Corner Piece RHS

M5 Button Head Screws (Black)

M5 Flat Washers (Black)

M6 Flat Washers

Rubber Washers

Star Washers

M6 Nylock Nuts

Header Rail Seal

Lock Striker Brackets

Jacking Brackets

M8x25mm Hex Head Bolts

M8 Spring Washers

M8x40mm Phillips Head Screws

M8 Flat Washers

M8 Nuts

Header Support Bracket LHS

Header Support Bracket RHS

Tapped Plates

Stud Plates

Component Name Qty

LIST OF PARTS

13/10/09

Clean Tonneau Cover with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

2

2

1

1

2

4

4

2

1

1

1

1

1

6

1

2

1

2

Item

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

Ball Stud Screws

Gas Struts

Hinge Pin LHS

Hinge Pin RHS

75mm x 75mm Foam Pads

M6x12mm Allen Head Screws (Black)

M6 Flat Washers (Black)

M6x25mm Allen Head Screws

Large Male Terminal Housing

Large Female Terminal Housing

Small Male Terminal Housing

Small Female Terminal Housing

Mastic Strip

Cable Ties

Vehicle Wiring Loom

Alcohol Wipes

Cable Tie Plinth

Keys (Taped to Underside of Tonneau)

Component Name Qty

Allen Key to suit M5, M6 & M8

Cleaning Cloth & Soapy Water

Drill with Ø25mm Holesaw

Torx Head Screwdriver & Bits

Phillips Head Screwdriver (#3)

Spanners & Sockets

Scissors/Sharp Knife

Non-acetic Silicon & Caulking Gun

Tape Measure & Masking Tape

RECOMMENDED TOOL LIST

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FORD FALCON UTE 08 3PC REMOTE LOCKING TONNEAU COVER

13/10/09

1 2 3 4 5 6

7 8 9 10 11 12

13 14 15 16 17 18

19 20 21 22 23 24

25 26 27 28 29 30

31 32 33 34 35 36

37 38

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.

4039

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WARNING!When in the closed position, Tonneau Cover must be locked and tailgate 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!

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 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.

ExclusionsThis warranty does not cover failure due to neglect, improper installation including any modifications to installation hardware, operating the vehicle with your EGR Tonneau Cover in the open position, alterations, addition of equipment, abuse, accident, corrosion, normal wear and tear, lack of maintenance, 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 responsibility of 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 replace the defective part. Transportation costs and labor are not associated with this warranty claim.

MaintenanceYour EGR Tonneau Cover only requires periodic cleaning with mild car wash soap. Only use cleaners, waxes, or products that are labeled safe for use on plastics. Avoid the use of any chemicals to clean your EGR 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.

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

TONNEAU COVER - IMPORTANT: • 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.• 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.

SPORTS BAR - IMPORTANT: Please take care when assembling and installing this product to protect the finish and your investment. To protect your investment, wax this product after installing. Regular waxing is recommended. Do not use any type of polish or wax that contains abrasives that could damage the finish.

Finish Protection: Our products have a high finish that must be maintained such as any other high finish product on the vehicle. Protect the finish with a non-abrasive automotive wax. The use of soap, polish, or wax that contains abrasives is detrimental, as the compounds scratch the finish and open it to corrosion. Metal polishes such as “Autosol” are recommended.

Disclaimer: The buyer assumes all risk and liability whatsoever from the installation and use of our products. Our products are sold as decorative accessories and should not be relied upon as protection for the vehicle or occupants in the event of a collision or rollover. The manufacturer assumes no liability for injury, loss, incidental or consequential damages in the event of a collision or rollover.

PAINTING INSTRUCTIONS (IF UNPAINTED)• 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.

FRONT

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1. NOTE: Two people are required to complete installation. Install the EGR Sports Bar attachment brackets to Step 11 of Sports Bar Fitting Instructions before installing the Tonneau Cover. Remove all Tie Downs (if fitted) from the vehicle as shown and Retain. Thoroughly clean and dry the installation areas. See Dia #1.

Diagram #1

IMPORTANT: Install the EGR Sports Bar to Step 11 of Sports Bar FittingInstructions before installing the Tonneau Cover.

1

3. Remove and discard the existing soft tonneau rail. Attach foam tape pad (Item 27) to the side rail end caps as shown. Ensure that it is aligned with the top of the front bed rail and the lip at the end of the side rail end cap as shown. Repeat process for the other side of the vehicle. See Dia #3.

Diagram #3

FOAM TAPEPAD

ALIGN

RHS SHOWN

REMOVE AND DISCARD EXISTINGSOFT TONNEAU RAIL

SIDE VIEW

FOAM TAPE

SIDE RAIL END CAPFRONT BEDRAIL

SIDE RAILEND CAP

2. Measure 70mm straight down from the empty hole in the side rail (2nd from the front) and drill a Ø25mm hole in the vehicle’s bedliner using a holesaw. See Dia #2.

Diagram #2

Ø25mm

SIDE RAIL

EMPTY HOLE(2ND FROM FRONT)

DRILL Ø25MM HOLE

RHS ONLY

70mm

FRONT

FRONT

TIE DOWN 1

2

HEADER RAILASSEMBLY

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6. Attach the header rail assembly (Item 2) to the vehicle’s front bed rail using the four (4) black M5 button head screws (Item 5), black M5 flat washers (Item 6) and rubber washers (Item 8) as shown. Tighten to torque 5Nm. See Dia #6.

Diagram #6

5. Fit the header rail assembly (Item 2) to the vehicle’s front bed rail as shown. See Dia #5.

Diagram #5

M5 BUTTONHEAD SCREW

(BLACK)

RUBBERWASHER

TORQUE 5Nm

M5 FLATWASHER(BLACK)

HEADER RAILASSEMBLY

SIDE VIEWHEADER RAIL

ASSEMBLY TAPPED PLATE

FRONTBED RAIL

THINFOAMTAPE

BEDLINER

HEADERSUPPORT

BRACKET LHS

4. Attach the header support brackets (Items 19 & 20) to the tapped plates (Item 21) using the black M6x12mm allen screws (Item 28), star washers (Item 9) and black M6 flat washers (Item 29) as shown (2-3 turns only). Slide the 2x header support bracket and tapped plate assemblies into the “T” slot in the header rail assembly (Item 2) as shown. See Dia #4.

Diagram #4

TAPPEDPLATE

HEADERSUPPORT

BRACKET LHS

M6x12SCREWS

M6 FLATWASHERS(BLACK)

STARWASHERSx2

1

HEADERRAIL ASSEMBLY

TAPPEDPLATE

HEADERSUPPORT

BRACKET LHS

LHS SHOWN SIDE VIEW2

TAPPEDPLATE

SLIDE

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8. Remove the torx head screw 4th from the front of the vehicle. IMPORTANT: Re-Tap hole with M6 Tap. Install the ball stud screw (Item 23) with the star washer (Item 9) and M6 flat washer(Item 7) as shown. Tighten to torque 10Nm. Repeat process for the other side of the vehicle. See Dia #8.

Diagram #8

9. Remove the torx head screw at the rear end of the side rail. Attach the stud plate (Item 22) to the side rail using the M6x20mm allen head screw (Item 30) and star washer (Item 9) as shown. Tighten to torque 7Nm. Attach the lock striker bracket (Item 12) to the stud plate using the two (2) M6 nylock nuts (Item 10) and M6 flat washers (Item 7) as shown. Do not tighten yet. Repeat process for the other side of the vehicle. See Dia #9.

Diagram #9

RHS SHOWN SIDE RAIL

SIDE RAIL SIDE VIEW REARFRONT

1 RHS SHOWN2

STARWASHER

TORQUE10NmTORX HEAD

SCREWREMOVE

BALL STUDSCREW

M6 FLATWASHER

7. Slide the header support bracket RHS (Item 20) along the header rail assembly (Item 2) so that it is hard against the front cam plate as shown. Hand tighten the black M6x12mm screws (Item 28). Repeat process for the other side of the vehicle. See Dia #7.

Diagram #7

RHS SHOWN

HEADERRAIL

ASSEMBLY

SLIDE

TAPPEDPLATE

HEADERSUPPORT

BRACKET RHS

M6x12SCREWS

FRONT CLAMPPLATE

RHS SHOWN

SIDE RAIL SIDE VIEW REARFRONT

1 RHS SHOWN2 RHS SHOWN3

TORX HEADSCREW

M6x20 ALLENSCREW

STUDPLATE

TORQUE7Nm

STAR WASHER

STUD PLATESIDE RAIL SIDE RAIL

M6 NUT

FLATWASHER

LOCK STRIKERBRACKET

2RE-TAP HOLE WITH M6 TAP.

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SPORTS BAR

CORNERPIECES

10. Fit corner pieces (Items 2 & 3) to the pre-assembled Sports Bar as shown. Loosely fasten corner pieces and jacking brackets (Item 13) in place using the M8x40mm phillips head screws (Item 16), M8 spring washers (Item 15) and M8 flat washers (Item 17) as shown. Finally, attach the M8x25mm hex head bolts (Item 14) and M8 nuts (Item 18) to the jacking brackets (Item 13) as shown. See Dia #10. NOTE: Corner piece will position itself when mounted to vehicle tub.

Diagram #10

1

1

12. Attach the Sports Bar to the rear clamp plate in two places using the M8x25mm screws, M8 spring washers and M8 flat washers from the Sports Bar hardware kit as shown. Tighten to torque 25Nm. Repeat process for the other side of the vehicle. See Dia #12.IMPORTANT: Finally, tighten all the screws attaching the corner pieces to the Sports Bar to torque 4Nm.

Diagram #12

SPORTSBAR

REAR CLAMP PLATE

GASKETCORNER PIECE

RETAINED SPORTSBAR HARDWARE

M8x25mmTORQUE

25Nm

RHS SHOWN

11. Position Sports Bar on vehicle using two people either side of the vehicle and lower the Sports Bar down so the feet tags are aligned inside the tub over the clamp plate positions. Using hardware from the Sports Bar hardware kit, attach the Sports Bar foot to the vehicle’s side rail using the M6x50mm screw, M6 spring washer and M6 flat washer into existing front hole in vehicle as shown. Tighten to torque 10Nm. Attach the Sports Bar to the front clamp plate using the M8x20mm screw, M8 spring washer and M8 flat washer as shown. Tighten to torque 25Nm. Tighten the previously installed M6x12mm allen head screws (Item 28) to torque 10Nm. Repeat process for the other side of the vehicle. See Dia #11.

Diagram #11

1RHS SHOWN2

RETAINED SPORTS BAR HARDWAREHEADER SUPPORT

BRACKET RHS

FRONT CLAMPPLATE

SPORTS BARFOOT

M8x20mmTORQUE

25Nm

M6x50mmTORQUE

10Nm

M6x12TORQUE

10Nm

RHS SHOWN

JACKINGBRACKET

CORNER PIECERHS

ATTACH LOOSELY

M8 SPRING WASHER

M8 FLAT WASHER

M8 SPRINGWASHER

M8 FLATWASHER

M8x40 PHILIPS SCREWS

M8x25 HEX HEAD BOLT

SPORTS BAR

M8 NUT

2

23

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13. Apply a small bead of non-acetic silicon to the slot in the header rail assembly (Item 2) at both ends, where the edge of the channel in the corner piece begins as shown. Apply soapy water to the bottom of the header rail seal (Item 11) and attach it to the back of the header rail assembly by pressing it down into the slot as shown. Ensure the header rail seal does not extend past the edge of the channel on both corner pieces (Items 2 & 3) as shown. Once it is in place, wipe the header rail seal dry. See Dia #13.

Diagram #13

HEADER RAILSEAL

HEADER RAILSEAL

SPORTS BAR

CORNERPIECE

ALIGN WITHEDGE OFCHANNEL

APPLYSOAPYWATER

2

SIDE VIEW

LHS SHOWN

HEADER RAILSEAL

HEADERRAIL

31

SILICON

CONTINUED OVER PAGE

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13/10/09

VEHICLE WIRING LOOM LOCATION DIAGRAM(USE AS A GUIDE ONLY - PROCEED THROUGH FITTING INSTRUCTIONS TO COMPLETE INSTALLATION)

RUBBER GROMMET INTO VEHICLE’S CABIN WIRE TERMINALS4 5

INSTALLATION:

GREY 4-WAY CONNECTOR

INSTALLATION:INSTALLATION:INSTALLATION:

8-WAY CONNECTORS & EARTH WIRE

GAS STRUT SPADE TERMINAL1 2 3

1

2

3

4 5

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Diagram #14

15. Remove the orange connector located behind the kick panel by pushing the grey lever forward and pulling the orange connector out as shown. See Dia #15.

Diagram #15

16. Lift the white secondary lock plate. Lift the terminal lance in both locations as shown above. Finally, remove the corresponding yellow wire with black stripe as well as the plain yellow wire. See Dia #16.

Diagram #16

PUSHGREY LEVER

LIFTWHITE SECONDARY LOCK PLATE

LIFTTERMINAL LANCE x2

REMOVEYELLOW WIRE WITH BLACK STRIPE

& PLAIN YELLOW WIRE

REMOVEORANGE

CONNECTOR

1 2

1 2 3

NOTE: The process of installing the vehicle wiring loom will be much easier if vehicle is on a hoist.

REMOVERUBBER SEAL

WIRING

14. Remove kick panel, scuff plate and the rubber door frame seal located in the driver’s side foot well as shown. See Dia #14.

DRIVER’S SIDE ONLY

1 2REMOVE

KICK PANELAND SCUFF PLATE

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17. Attach the small and large male terminal housings (Items 31 & 33) to the two (2) previously removed wires as shown. Be sure to depress the secondary lock plate on each terminal housing. See Dia #17.

Diagram #17

18. Remove the vehicle’s rear wheel splash guard (RHS only). Locate the grey 8-way connectors and disconnect them as shown. See Dia #18.

Diagram #18

19. Remove the vehicle wiring loom (Item 37) from its packaging and it lay it out on the ground. Locate the eyelet terminal on the loom and attach it to the earth wire terminal near the previously disconnected 8-way connectors as shown. See Dia #19.

Diagram #19

1 2

DISCONNECTREMOVEREAR WHEEL

SPLASH GUARD

FRONT OFVEHICLE

GREY 8-WAYCONNECTORS

UNDO BOLT1

RE-ATTACH BOLT3

ATTACHEARTH WIRE EYELET

(VEHICLE WIRING LOOM)

2

RHS ONLY

1 2MALE TERMINAL

HOUSINGS

DEPRESSSECONDARYLOCK PLATES

SMALL MALETERMINALHOUSING

YELLOWWIRE

YELLOW WIREWITH BLACK

STRIPE

LARGEMALE

TERMINALHOUSING

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20. Connect the grey 8-way connectors from the Tonneau adapter harness wiring loom (Item 37) to the previously disconnected connectors on the vehicle near the earth wire terminal as shown. See Dia #20.

Diagram #20

21. Reach up into the RHS wheel arch - between the outer sheet metal and the bedliner - to feed the wiring loom spade terminal through the hole in the side rail just forward of the gas strut position, and tape in place as shown. Cable-tie (Item 36) the wiring loom (Item 37 into position inside the wheel well in two (2) locations as shown. See Dia #21.

Diagram #21

22. Feed the grey 4-way connector through the previously drilled hole in the bedliner and push the rubber grommet into place. Cable-tie (Item 36) the lower section of conduit to the existing vehicle loom in three (3) locations forward of the wheel well as shown.See Dia #22. NOTE: It may be difficult to feed the 4-way connector through the bedliner due to limited space in the wheel well. If this is the case, feed a pull wire from inside the tub down the hole in the bedliner, attach it to the 4-way connector and pull it back through.

Diagram #22

CONNECTGREY 8-WAY

CONNECTORS

EARTHWIRE TONNEAU ADAPTER HARNESS

WIRING LOOM PROVIDEDIN TONNEAU HARDWARE KIT

(SHADED)

CONNECTGREY 8-WAY CONNECTORS

PREVIOUSLYDISCONNECTED

CONNECTOR

PREVIOUSLYDISCONNECTED

CONNECTOR

12

FEEDGREY 4-WAY CONNECTOR

THROUGH HOLE

PUSHRUBBER GROMMET

INTO HOLE

RHS SHOWN 3 WIRING LOOM(SHADED)

ATTACHCABLE TIES(3 PLACES)

TO GREY4-WAY

CONNECTOR(THROUGHBEDLINER)

EXISTINGVEHICLE

LOOM

SIDE RAIL

ATTACHCABLE TIE

WIRING LOOM RHS WHEEL ARCH AREA

(SHADED)

1 2

ATTACHCABLE TIE

GREY 8-WAYCONNECTOR

FEEDGAS STRUT SPADE

TAPE

TERMINAL THROUGH HOLEAND TAPE IT IN PLACE

SIDE RAIL

RHS SHOWN

REAR OFVEHICLE

23. Feed the taped terminals on the wiring loom (Item 37) through the rubber grommet and into the vehicle’s cabin. From inside the vehicle’s cabin, flex out the carpet trim RHS wall to gain access to the rubber grommet and pull the taped terminals through.See Dia #23. IMPORTANT: Be careful not to damage the existing vehicle wiring harness.

Diagram #23

24. Run a pull wire (not provided) between the b-pillar trim and sheet metal as shown. Attach the pull wire to the wiring loom (Item 37) and pull it through. Finally, run the loom under the scuff plate and lip to the orange connector area as shown. See Dia #24.

Diagram #24

25. Remove the tape from the terminals on the wiring loom (Item 37). Insert the male wiring loom terminals into the female terminal housings (Items 32 & 34) provided. Finally, depress the secondary lock plates on the bottom of the female terminal housings.See Dia #25.

Diagram #25

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RUBBER GROMMETLOCATION

B-PILLAR TRIM SEAT BELT

FLEXED CARPET TRIMRHS WALL

VEHICLE WIRING LOOM

ATTACH A PULL WIRE(NOT PROVIDED)TO LOOM HERE

PULL WIRING LOOM THROUGH BETWEENB-PILLAR TRIM & SHEET METAL & THEN

UNDER SCUFF PLATE & LIP TOORANGE CONNECTOR AREA

PULLWIRE

B-PILLAR SHEETMETAL

1

2

1 2INSERT

WIRING LOOMTERMINALS

FEMALE TERMINALHOUSINGS


DEPRESSSECONDARYLOCK PLATES

B-PILLAR

FLEX OUTCARPET TRIM

RHS WALL

DRIVER’SSEAT

31

PULL THROUGHTAPED WIRING

TERMINALS

2

RUBBERGROMMETLOCATION

RHS REAR WALLOF CABIN

FEEDTAPED TERMINALSTHROUGH RUBBER

GROMMET

WIRING LOOM

RUBBERGROMMET

(AT BACK OFREAR OF CABIN)

26. Ensure the white secondary lock plate on the orange connector is in unlocked position. Insert the brown and orange female wire terminals on the wiring loom (Item 37) into the orange connector at same locations that previous terminals were removed from. Finally, close the white secondary lock plate as shown. See Dia #26.

Diagram #26

27. Insert the male terminal housings (Items 31 & 33) on the existing wiring loom into the female terminal housings (Items 32 & 34) on the vehicle wiring loom (Item 37) as shown. Re-connect the orange connector halves and lock them in position by pushing the grey lever back into place. See Dia #27.

Diagram #27

Diagram #28

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13/10/09

ENSURE WHITE SECONDARY LOCKPLATE IS IN UNLOCKED POSITION

1 2 3 CLOSEWHITE SECONDARY LOCK PLATE

ORANGEWIRE

ORANGECONNECTOR

BROWN WIRE

1 2 3INSERT

MALE TERMINALHOUSINGS



RE-CONNECTORANGE

CONNECTOR HALVES

PUSHGREY LEVERBACK INTO

PLACE

1

SEALGROMMETHOLE WITH

MASTIC

INSERTTERMINALS

28. Seal the hole in the rubber grommet with the Mastic strip (Item 35) provided. Replace the carpet trim side wall, the rubber door frame seal and the kick panel and scuff plate as shown. See Dia #28.

2REASSEMBLE

TRIM ITEMS

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31. Attach the gas struts (Item 24) by clipping them into place as shown. ENSURE THE NARROW END MOUNTS TO THE VEHICLE. Connect the vehicle wiring loom (Item 37) to the terminals on the driver’s side gas strut as shown. See Dia #31.NOTE: Attach gas strut with terminals to the driver’s side of the vehicle.

Diagram #31

NEXT STEPRE-TORQUE 7Nm

ENSURECLEARANCE

TO TUB

LOOSEN HINGE SCREWSTO ADJUST TONNEAU

POSITION IF NECESSARY

1 2 2

29. Open vehicle’s tailgate. Fit Tonneau Cover (Item 1) and secure hinges with hinge pins (Items 25 & 26) as shown. See Dia #29.

Diagram #29

2

1

IMPORTANT: Ensure vehicle’s tailgate is opened before installing Tonneau Cover,as locking mechanism may not function until adjusted correctly.

LHS SHOWN4LHS SHOWN3

“CLICK”

30. Check Tonneau Cover (Item 1) is central to vehicle and the sides of Tonneau Cover do not contact the vehicle bed rail. Measure the distance between the edge of the Tonneau Cover and the vehicle all the way around the tub, ensuring all distances are equal. Adjust position if necessary by loosening the top hinge screws and re-positioning Tonneau Cover to fit centrally on vehicle. Re-tighten hinges to torque 7Nm. See Dia #30. NOTE: Ensure that the gas struts (Item 24) are not attached to the Tonneau Cover during this process.

Diagram #30

ENSURE NARROWEND OF GAS

STRUT MOUNTSTO VEHICLE

HINGE PIN HINGE PIN

HEADERRAIL

HEADERRAIL

DRIVER’S SIDE ONLY2 DRIVER’S SIDE ONLY3

GAS STRUTBOTTOM

GASSTRUT

TOP

VEHICLEWIRINGLOOM

TONNEAUWIRINGLOOM

GAS STRUT1

32. Loosen the screw found on the terminal housing on the driver’s side gas strut (Item 24), until it can move up and down the strut freely. With the tailgate open, gently close the Tonneau Cover (Item 1). 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 #32.

Diagram #32

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34. Adjust M8x25mm bolt (Item 14) in jacking bracket (Item 13) until corner piece (Items 3 & 4) is level with the main surface of the Tonneau Cover (Item 1). Once in the correct position, lock the M8 nut (Item 18) into position against the bracket using a spanner. Repeat for the other side of vehicle. See Dia #34.

Diagram #34

RHS SHOWN1 2

CORNERPIECE

M8x25mmHEX HEAD

BOLTM8 NUT

JACKING BRACKET

ALIGNED

TONNEAUCOVER

GENTLYCLOSE

TONNEAULOOSENSCREW

OPENTONNEAU

COVER

1 2 43 5

ENSURE CONTACTHAS BEEN MADE

GASSTRUT

CYLINDER

TIGHTENSCREW

33. If EGR Spoiler is to be fitted to the Tonneau Cover (Item 1), complete now (by referring to the Spoiler Fitting Instructions) before proceeding to the next Diagram. See Dia #33.

Diagram #33

IMPORTANT: If EGR Spoiler is to be fitted to the Tonneau Cover,complete now before proceeding to the next step.

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

Diagram #35

36. Close Tonneau Cover (Item 1) and inspect locking mechanism. Ensure the latch hits the striker bracket (Item 12) centrally. If it DOES NOT, adjust the latch accordingly by loosening the screws and moving the latch left or right as shown. Tighten to torque 5Nm. You may also need to adjust the height of the lock striker bracket by loosening the M6 nuts (Item 10) and moving it up or down as shown. Once you are satisfied with the position of the lock striker, tighten to torque 10Nm. See Dia #36. Note: Tonneau Cover has 2 stage locks. Ensure Tonneau engages with second stage of the latch.

Diagram #36

1

INCORRECT

INSPECT LATCHENGAGEMENT

CORRECT

2 ADJUST STRIKER BRACKET4ADJUST LATCHMECHANISM

3

LOOSENM6 NUTS

LOCKSTRIKERBRACKET

ADJUSTTORQUE 10Nm

SCREWS

TORQUE 5Nm

ADJUST

Diagram #37

ENGAGE LOCK

LATCH MECHANISM

PRESS LATCHUPWARDS

ROTATE PULLRODS

CLOCKWISE = SHORTENANTI-CLOCKWISE = LENGTHEN

“CLICK”

2 ADJUST LENGTH OFPULLRODS BY ROTATION

3 4

REPLACE INSPECTION COVER6

TEST LOCKING MECHANISM5

RETAINERCLIPS

LOCK PLASTIC RETAINER CLIPSBACK IN POSITION

1

35. Remove inspection cover by removing scrivets and rotating cover anti-clockwise. Release plastic retainer clips and unclip rods as shown. See Dia #35.

INSPECTION COVERPLASTIC RETAINER

CLIPSRODS

REMOVE INSPECTIONCOVER

1 RELEASE PLACTICRETAINER CLIPS

2 UNCLIP RODS FROMPLASTIC RETAINERCLIPS

3

37. Open the Tonneau Cover (Item 1) and engage the lock by pressing upwards on the latch. Adjust pullrods 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 pullrods 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 pullrods. If it DOES release, replace inspection cover. See Dia #37.

INSPECTIONCOVER

Diagram #38

39. Manually lock and unlock the Tonneau Cover (Item 1) using the key supplied (Item 39) (Tonneau Cover is supplied in the unlocked position). 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 #39.

Diagram #39

40. Open and close the Tonneau Cover (Item 1) 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 #32). See Dia #40.

Diagram #40

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TONNEAU COVERINTERIOR LIGHT

TONNEAULOCKED

TONNEAUUNLOCKED

38. Join the two halves of the grey 4-way connectors located at the front of the tub as shown. Adhere Cable Tie Plinth to Header Rail halfway between wiring loom exit point on Tonneau and the Tub side wall. Secure Vehicle Wiring Harness using Cable. See Dia #38.

GREY 4-WAYMALE CONNECTOR


4-WAY FEMALECONNECTOR

(TONNEAU COVER)

CABLE TIE PLINTH

41. Pull the pull release tag handle to ensure it functions correctly. If it DOES NOT, return to Diagram #37 to make further adjustments to the pullrods, to remove freeplay in pullrods. Pulling the release tag must fully release both LHS and RHS latches.See Dia #41.

Diagram #41

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UNDERSIDE OF TONNEAU COVER

PULL RELEASE TAG

PULL

INSPECTIONCOVER

42. Replace the vehicle’s rear wheel splash guard (RHS only). Replace Tie Downs ensuring they are clear of the Tonneau Cover and Hardware. See Dia #42. Note: Check Tonneau does not contact Tie Downs in the OPEN & CLOSED Positions.

Diagram #42

REPLACEREAR WHEEL

SPLASH GUARD

FRONT OFVEHICLE

RHS ONLY

TIE DOWN

12

1. Open Tonneau Cover (Item 1), pull the 4-way connectors out from behind the bedliner and disconnect them. Disconnect the vehicle wiring loom (Item 37) from the terminals on the driver’s side gas strut (Item 24). 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 (Items 25 & 26) and then remove the Tonneau Cover (Item 1) as shown. See Dia #2.

Diagram #2

REMOVAL OF TONNEAU COVER

31 2

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LHS SHOWN LHS SHOWN

BALL STRUT SCREW

GASSTRUT

4

5

3

1 GAS STRUT

DRIVER’S SIDE ONLY

GAS STRUTBOTTOM

GASSTRUT

TOP

WIRINGHARNESS

2

4-WAYCONNECTORS

UNDERSIDE OFTONNEAU COVER

TO REPLACE THE TONNEAU COVER:Reverse the sequence and the procedures of the two (2) Diagrams above.

HINGE PINHINGE PIN

HEADERRAIL

HEADERRAIL

tc0143b 3pc tonneau cover with remote locking … falcon fg 3p... · 2014-03-24 · tc0143b page 6...

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