hard tonneau cover - EGR DealerNet [www.egrdealernet.com]

TC0167
HARD TONNEAU COVER
Part Number: 92240315
Contents
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
Qty
Tonneau Cover
1
Left Hand Corner Piece
1
Right Hand Corner Piece
1
Drill Template
1
Hinge Base Plates
2
Hinge Pins
2
Hinge Pin Locking Tabs
2
Countersunk Self-tapping Screws 2
Rubber Extrusion
1
Small Rubber Extrusion Pieces
2
Ball Stud Screws
2
Lock Striker Brackets
2
Striker U-Bolts
2
1
2
Item
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Description
Flat Washers
Nuts
Pop Rivets
Gas Struts
Nut Inserts (4 Spare)
20mm Allen Screws
Fibre Washers
Wiring Harness
Allen Key
Alcohol Wipe
Rust Inhibitor
Keys
Nut Insert Toolkit
Water Deflector
3
Qty
8
8
2
2
12
8
8
1
1
1
1
2
1
1
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
AUTOMOTIVE
SURF
ACE CLEA
NER
For use in cleaning
painted metal,
glass and other
vehicle surfaces
.
For external
use only.
Dispose of properly
after use.
IMPREGNATED
WITH 70%
24
25
26
ISOPROPYL ALCOHOL
27
PLACE THESE INSTRUCTIONS IN VEHICLE’S GLOVE BOX AFTER INSTALLATION IS COMPLETE.
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Tools Required
• Drill with Ø5mm, Ø10mm & 3/16” Drill Bits
• Torque Wrench (1/4” Drive)
• Rivet Gun
• Torx Head Screwdriver & Bits
• Caulking Gun
• Non-Acetic Silicone
•
•
•
•
•
•
Wrench with 10mm & 13mm Socket
13mm Spanner
Phillips Head Screwdriver
Tape Measure & 6” Steel Rule
Non-Permanent Marker
Masking Tape
Caution
Care Instructions:
Clean Tonneau Cover with a mild
detergent and water solution.
Do not use abrasive
cleaners or solvents.
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!
MAINTENANCE
Your 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 Tonneau Cover unless labelled safe for plastics.
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. Gas struts must be orientated in open Tonneau position with the shaft end attached to the tub.
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.
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.
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.
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Installation Instructions
1. NOTE: Two people are required to complete installation. Read instructions thoroughly before commencing
fitment. Thoroughly clean and dry the installation areas. Refer to figure #1.
FIGURE 1
2. Using a non-permanent marker, find and mark the centre point of the header rail using a tape measure. Position the
drill template on top of header rail, aligning the edge correctly with the rear window and the notch in the centre with
the marked centre point on the header rail as shown. Refer to figure #2. IMPORTANT: Re-check the centre
point of the header rail has been marked correctly. Drill template MUST be centre.
DRILL
TEMPLATE
DRILL TEMPLATE
INDOW
REAR W
2
2
CENTRE POINT
MARKED ON
HEADER RAIL
NOTCH IN
CENTRE OF
DRILL TEMPLATE
1
FIND AND MARK HEADER RAIL CENTRE POINT
FIGURE 2
3. Fit hinge base plates into cut-out in drill template as shown. Mark four (4) holes in front of hinge base plate. Remove
hinge base plates. Centre punch previously marked holes and drill Ø5mm holes, followed by Ø10mm holes at the
eight (8) positions. Remove any swarf and apply rust inhibitor to all the drilled holes. Do not remove drill template at
this time. Refer to figure #3.
2
1
4
3
FIT
REMOVE
5
7
6
Ø5mm
DRILL TEMPLATE
Ø10mm
HINGE
BASE
PLATE
DRILL TEMPLATE
10mm
MARK, CENTRE PUNCH,
DRILL Ø5mm THEN
Ø10mm HOLES &
APPLY RUST INHIBITOR
FIGURE 3
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THIS STEP IS VERY IMPORTANT, PLEASE TAKE THE TIME TO ENSURE
THAT IT IS DONE CORRECTLY.
NOTE: IF YOUR WORKSHOP WILL BE INSTALLING MORE OF THESE TONNEAU
COVERS IT IS RECOMMENDED THAT YOU PURCHASE A PNEUMATIC TOOL TO
ASSIST WITH THIS PROCESS. THIS PNEUMATIC TOOL WILL BOTH ENSURE THE
NUTSERTS ARE INSTALLED CORRECTLY AND SUBSTANTIALLY REDUCE
INSTALLATION TIME FOR THIS STEP. DETAILS FOR THE RECOMMENDED TOOL
IS AS FOLLOWS:
PRODUCT NAME: THREADED INSERT FASTENING TOOL
MODEL NUMBER: 74200
MANUFACTURER: TEXTRON FASTENING SYSTEMS PTY LTD
ADDRESS: 891 WELLINGTON ROAD, ROWVILLE, VICTORIA, 3178.
CONTACT: PH 03 9764 3877 FAX 03 9755 7352
4. Assemble Nut-insert Toolkit as shown, screwing the LEFT HAND THREADED tool-bolt male, into the tool-nut
female until finger tight. Insert the nut-insert fully into drilled hole in header rail. While holding the tool-nut female
in place with a 13mm spanner, tighten the tool-bolt male, clockwise until the nut-insert collapses completely in the
drilled hole (the nut insert is collapsed when the torque reaches approx 6Nm). Remove M6 Hex bolt. Repeat
process for the remaining seven (7) drilled holes. Refer to figure #4.
1
FIBRE WASHER
METAL WASHER
2
HEADER RAIL
3
13mm
HEX HEAD
BOLT
NUT
INSERT
TOOL-NUT
FEMALE
TOOL-BOLT
MALE
4
NUT-INSERT
TOOLKIT
NUT
INSERT
10mm
ROTATE
CLOCK-WISE
13MM
UNTIL TIGHT
SPANNER
(HOLD NUT) (WITH 13MM
SOCKET)
13mm
NUT-INSERT
TOOLKIT
HEADER RAIL
REMOVE
NUT-INSERT REMOVE
TOOLKIT
HEX HEAD
BOLT
FIGURE 4
5. Apply non-acetic silicon to the underside of the hinge base plates and position on the vehicle, aligning the four (4)
holes on the hinge with those on the header rail as well as inside the cut-out of the drill template. Position hinge pin
locking tabs with the tabs to the left hand of the hinge base plate across the top two fixing holes. Use the allen screws
and fibre washers supplied to secure the hinges. Tighten to torque 8Nm. Refer to figure #5.
1
HINGE
BASE
PLATE
NON-ACETIC
SILICON &
CAULKING GUN
3
2
2
HINGE BASE PLATE
HINGE BASE
PLATES
HINGE PIN
LOCKING TAB
TORQUE 8Nm
DRILL TEMPLATE
FIBRE WASHERS
ALLEN SCREWS
FIGURE 5
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6. Drive the countersunk self-tapping screw through the hole in the top surface both of the hinge base plates.
Tighten to torque 3Nm. Refer to figure #6.
COUNTERSUNK
SELF-TAPPING
SCREWS
TORQUE 3Nm
HINGE BASE
PLATE
FIGURE 6
7. Remove the three (3) tie-down brackets on the right hand of the bed using a torx-head screwdriver as shown.
Refer to figure #7.
RIGHT HAND VIEW INSIDE VEHICLE TUB
TIE-DOWN BRACKETS
TORX HEAD SCREWS
FIGURE 7
8. Open the vehicle’s tailgate. Remove the two (2) push rivets and peel back the rubber tailgate seal as far as the base
of the tailgate as shown. Refer to figure #8.
TAILGATE
SEAL
1
PUSH
RIVETS
2
3
2
FIGURE 8
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9. Lift and pull the bedliner as shown to gain access to the wiring located in the side panel of the vehicle. Disconnect
the stop light wiring plug located behind the bedliner, by pushing down on the tag on the connector using your finger
or a flat blade screwdriver. Refer to figure #9.
NOTE: This connector is located above the wheel arch towards the rear of the vehicle.
1
2
DISCON
NECT
TAILGATE
SEAL
BEDLINER
STOP LIGHT
WIRING PLUG
BEDLINER
FIGURE 9
10. Insert the wiring harness supplied in hardware kit between the two stop light wiring plugs as shown.
Refer to figure #10.
CO
STOP LIGHT
WIRING PLUG
NN
EC
T
CO
NN
EC
T
WIRING HARNESS
SUPPLIED IN
HARDWARE KIT
STOP LIGHT
WIRING PLUG
FIGURE 10
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 either of the white 2-way connectors back to where
they were previously unclipped from the vehicle. Refer to figure #11.
1
2
2-WAY
CONNECTORS
(VEHICLE)
UNCLIP FROM
MOUNT
3
CONNECT
2-WAY
CONNECTORS
(WIRING HARNESS)
2-WAY
CONNECTORS
(VEHICLE)
2-WAY
CONNECTORS
(VEHICLE)
CONNECT
DISCONNECT
FIGURE 11
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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
removed. While holding everything in place, re-attach the bolt to the earth wire terminal on the vehicle as shown.
Refer to figure #12.
1
2
EARTH WIRE
TERMINAL
(WIRING
HARNESS)
EARTH WIRE
TERMINAL
(VEHICLE)
3
RE-ATTACH
BOLT
REMOVE
BOLT
BOLT
BOLT
FIGURE 12
13. Find the middle tie down bracket hole and push the spade terminal from the wiring harness through it as shown.
Refer to figure #13.
MIDDLE TIE DOWN BRACKET HOLE
PUSH SPADE TERMINAL THROUGH
HOLE IN BEDLINER
SPADE TERMINAL
(WIRING HARNESS)
FIGURE 13
14. Run the grey 4-way connector from the 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.
Refer to figure #14.
4-WAY GREY CONNECTOR
(WIRING HARNESS)
4-WAY GREY
CONNECTOR
WIRING HARNESS
(BEHIND BEDLINER)
200mm
WIRING HARNESS
FIGURE 14
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15. Re-attach the bedliner by lifting it back into position, re-install the front tie-down bracket as shown (torque 10Nm),
the push rivets and the tailgate seal as shown. Refer to figure #15.
RIGHT HAND VIEW INSIDE
VEHICLE TUB
TIE-DOWN
BRACKET
TAILGATE
SEAL
2
1
3
PUSH
RIVETS
TORX HEAD
SCREW
(TORQUE 10Nm)
2
FIGURE 15
16. Note the small cut-out section in the drill template at each corner. Clean the vehicle paint surface at this area with
alcohol wipe provided, and the area adjacent on the vehicle sail-plane panel. Wipe dry with a clean cloth. Remove the
protective liner from the back of the small rubber extrusion piece. Attach it to the vehicle according to the diagram
above, fitting it into cut-out in drill template as shown, and across the vehicle sail-plane panel. Rub down firmly to
ensure good adhesion of tape. Repeat for other side, then finally remove the drill template. Refer to figure #16.
1
2 RIGHT HAND SHOWN
SMALL RUBBER
EXTRUSION
PIECE
DRILL
TEMPLATE
SIDE VIEW
FRONT OF
VEHICLE
HEADER RAIL
FIGURE 16
17-A. Note the tape attachment areas on the corner piece and their respective areas of adhesion to the vehicle. Clean
these areas with the alcohol wipe provided and wipe away any residue with a dry, clean cloth. Apply approx 6mm
bead of non-acetic silicon to the corner piece as shown. Refer to figure #17-A.
1 RIGHT HAND SHOWN
CLEAN
AREAS
2
APPLY APPROX 6mm
BEAD OF SILICON
(AS INDICATED BY
SHADED AREAS)
CORNER
PIECE
FIGURE 17- A
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17-B. Remove the tape lining from the underside of the corner piece. Fit the corner piece to the vehicle as shown. Rub
down tape areas thoroughly with a soft clean cloth to ensure good adhesion. Immediately clean up any silicon that
squeezes out of the corner piece with a clean cloth and alcohol wipe. Repeat steps 17-A & 17-B for the other side
of the vehicle. Refer to figure #17-B.
(CONTINUED FROM PREVIOUS PAGE)
4 RIGHT HAND SHOWN
3
OF
E
E
ID IEC
S
ER R P
D
E
UN RN
CO
RIGHT HAND
CORNER PIECE
FIT
REMOVE
TAPE LINING
FIGURE 17-B
18. Clean the top surface of the header rail with the alcohol wipe provided & wipe away residue with a dry, clean cloth.
Trial-fit the rubber extrusion to the header rail, aligning it with the back of the hinges and corner pieces. Using a
non-permanent marker, draw a line along the length of the extrusion as shown. Remove the protective lining from
the extrusion and attach it to the header rail, keeping to the previously marked line. Rub down firmly to ensure good
adhesion. Refer to figure #18.
IMPORTANT: Ensure the slant in the rubber extrusion is facing towards the rear of the vehicle.
2 TRIAL-FIT RUBBER EXTRUSION
SIDE VIEW
3 MARK LINE ALONG EXTRUSION
ALCOHOL WIPE
1
4 REMOVE PROTECTIVE LINING
RUBBER
EXTRUSION
5 ATTACH RUBBER EXTRUSION
MARK LINE
EXTRUSION
CONTINUE ALONG LENGTH OF HEADER RAIL
FIGURE 18
19. Apply non-acetic silicon (not supplied) to the corner pieces, rubber extrusions, vehicle and header rail as shown.
The sealant is used to close up gaps in the assembly to prevent water entering the vehicle bed area.
Refer to figure #19. NOTE: Ensure the bead of silicon does not protrude through the gap between the corner
piece and the vehicle to become visible from above the corner piece.
RIGHT HAND SHOWN
CORNER
PIECE
NOT SUPPLIED
SILICON
FIGURE 19
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20. Trial fit Water Deflector between painted header rail panel and bedliner as shown with the Water Deflector protruding
approximately 15mm out from the header rail. Note tape attachment areas. Remove and clean the header rail in tape
areas as noted, with the alcohol wipe provided & wipe away any residue with a dry, clean cloth. Remove (x5) tape
liners from Water Deflector. Install between header rail panel & Bed Liner as shown and apply firm pressure to Water
Deflector over tape areas to ensure maximum adhesion to vehicle. Refer to figure #20.
Important : The tape adheres to the painted panel of the vehicle, not the bed liner.
Cross Section - Cut between the Hinges
looking towards RHS of Vehicle
HEADER RAIL
PAINTED PANEL
WATER
DEFLECTOR
15mm
REMOVE (x5)
TAPE LINERS
BEDLINER
FIGURE 20
21. Attach ball stud screw through previously removed middle Tie Down Bracket and screw into existing hole as shown.
Ensure there is at least 150mm of the spade terminal protruding through the bedliner and that it is positioned at the
rear of the bracket and half way up the edge of the bracket. Tighten to torque 10Nm. Repeat process for the other
side of the vehicle. Refer to figure #21.
TIE-DOWN
BRACKET
RIGHT HAND SHOWN
150mm
BALL STUD
SCREW
TORQUE 4Nm
SPADE
TERMINAL
FIGURE 21
22. Assemble striker U-bolt, washers and nuts onto striker bracket as shown and finger tighten the nuts ready for
adjustment later. Refer to figure #22. NOTE: There are left hand and right hand style lock strikers.
1
RIGHT HAND SHOWN
2
RIGHT HAND SHOWN
FIGURE 22
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23. Assemble the Lock Striker Bracket between the tie down bracket and vehicle tub as shown, use a ruler to level the top
edge of the bracket with the top of the vehicle, then fully tighten to 10Nm. Refer to figure #23.
RIGHT HAND SHOWN
FIGURE 23
24. Now that the lock striker bracket has been positioned correctly, Drill a Ø5mm hole through the bracket and into the
vehicle tub liner, using bracket hole as a guide. Then fasten the bracket into place, to the tub liner using a pop rivet
as shown. Repeat process for the other side of the vehicle. Refer to figure #24.
RIGHT HAND SHOWN
Ø5mm
DRILL Ø5mm HOLE,
& INSTALL POP RIVET
FIGURE 24
IMPORTANT: Ensure vehicles’s tailgate is opened before installing Tonneau Cover,
as locking mechanism may not function until adjusted correctly.
25. Open vehicle’s tailgate. Fit Tonneau Cover and secure hinges with hinge pins as shown. Refer to figure #25.
2
3 RIGHT HAND SHOWN
4 RIGHT HAND SHOWN
HINGE
PIN
HINGE
PIN
1
“CLICK”
FIGURE 25
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26. Check Tonneau Cover is central to vehicle and the sides of Tonneau Cover do not contact the vehicle bed rail.
Adjust position if necessary by loosening the top hinge screws and re-positioning Tonneau Cover to fit centrally on
vehicle. Re-tighten hinge screws to torque 5Nm. Refer to figure #26.
1
2
2
ENSURE
CLEARANCE
TO TUB
LOOSEN HINGE SCREWS
RE-TORQUE 5Nm
TO ADJUST TONNEAU
POSITION IF NECESSARY
NEXT STEP
FIGURE 26
27. Attach the gas struts by clipping them into place as shown. Ensure the narrow end mounts to the vehicle. Connect the
wiring harness to the terminals on the driver’s side gas strut as shown. Refer to figure #27.
NOTE: Attach gas strut with terminals to the driver’s side of the vehicle.
1
LARGE
END
2 DRIVER’S SIDE ONLY
GAS
STRUT
WIRING
HARNESS
NARROW
END
BALL STUD
GAS STRUT
BOTTOM
GAS
STRUT
TOP
FIGURE 27
IMPORTANT: Ensure vehicles tailgate remains open whilst adjusting Tonneau Cover locking mechanism.
28. Close Tonneau Cover and inspect locking mechanism. Ensure the latch hits the striker bracket centrally. If it DOES
NOT, adjust the striker bracket accordingly by loosening the M6 Nuts and moving the bracket up or down as shown.
Once adjustment is complete, tighten the M6 nuts on the lock striker brackets to 4Nm. Refer to figure #28.
IMPORTANT: Tonneau Cover has 2 stage locks. Ensure Tonneau engages with second stage of the latch.
For best results, spend time to tune the lock striker position up and down to provide minimal movement
when the tonneau is fully closed with the tailgate up in the closed position.
2 INSPECT LATCH
ENGAGEMENT
INCORRECT
3 ADJUST STRIKER BRACKET
LOCK STRIKER
ADJUST
U-BOLT
1
CORRECT
LOOSEN
NUTS
4
IF THE HORIZONTAL
POSITION OF THE LATCH
MECHANISM REQUIRES
ADJUSTMENT,
PLEASE PROCEED TO
DIAGRAM #29
OTHERWISE #33
FIGURE 28
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IMPORTANT: If the horizontal position of the latch mechanism requires adjustment,
proceed to Diagram #29 below, otherwise proceed to Diagram #33.
29. Remove inspection cover by removing the scrivets, and rotating the cover. Unclip the rod from the actuator and
letting it hang from the lock mechanism. Detach the actuator from the Tonneau Cover by removing the two (2)
screws as shown. Refer to figure #29.
1 REMOVE INSPECTION 2 DETACH ROD FROM
ACTUATOR
COVER
3 DETACH THE ACTUATOR
& BRACKET
UNCLIP
ROD
INSPECTION COVER
SCREWS
FIGURE 29
30. Remove the actuator from the inspection area and let it hang out of the hole as shown. Release plastic retainer clips
and unclip rods as shown. Adjust the latch mechanism by loosening the screws and moving it left or right as shown.
Once adjustment is complete, tighten the screws on the Tonneau latches to 4Nm. Refer to figure #30.
1 REMOVE ACTUATOR FROM
INSPECTION AREA
2 RELEASE PLASTIC
RETAINER CLIPS
3 UNCLIP RODS FROM
PLASTIC RETAINER
CLIPS
4 ADJUST LATCH
MECHANISM
ADJUST
ACTUATOR
PLASTIC
RETAINER
CLIPS
RODS
SCREWS
TORQUE 4Nm
FIGURE 30
31. Open the Tonneau Cover 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. Refer to figure #31.
2 ENGAGE LOCK
3 ADJUST LENGTH OF
PULLRODS BY ROTATION
4 LOCK PLASTIC RETAINER CLIPS
BACK IN POSITION
LATCH
MECHANISM
1
“CLICK”
PRESS LATCH
UPWARDS
ROTATE
PULLRODS
CLOCKWISE = SHORTEN
ANTI-CLOCKWISE = LENGTHEN
RETAINER
CLIPS
5 TEST LOCKING MECHANISM
FIGURE 31
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32. Re-attach the actuator to the inside of the Tonneau Cover using the previously removed screws. NOTE: Ensure you
hold the actuator in place while replacing the screws. Re-attach the rod to the actuator by clipping it back into
place as shown. IMPORTANT: Ensure the ball stud cam positions behind the butterfly latch as shown. If
required, loosen actuator screws and adjust length and position. Re-tighten screws to 4Nm. Refer to figure #32.
1 RE-ATTACH ACTUATOR
TO TONNEAU COVER
2 RE-ATTACH ROD TO
ACTUATOR
3 CHECK BALL STUD
CAM POSITION IS BEHIND
BUTTERFLY LATCH
BUTTERFLY
LATCH
CLIP
BALL STUD
CAM
TORQUE 4Nm
ROD
SCREWS
FIGURE 32
33. 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. Refer to figure #33.
1
2
GENTLY
CLOSE
TONNEAU
LOOSEN
SCREW
3
4
ENSURE CONTACT
HAS BEEN MADE
5
OPEN
TONNEAU
COVER
TIGHTEN
SCREW
GAS
STRUT
CYLINDER
FIGURE 33
34. 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. Refer to figure #34.
4-WAY FEMALE
CONNECTOR
(TONNEAU COVER)
4-WAY MALE
CONNECTOR
(WIRING HARNESS)
FIGURE 34
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35. Manually lock and unlock the Tonneau Cover using the key supplied (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. Refer to figure #35.
REPLACE INSPECTION
COVER
TONNEAU
LOCKED
INSPECTION
COVER
TONNEAU
UNLOCKED
FIGURE 35
36. 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 figure #33). Refer to figure #36.
TONNEAU COVER
INTERIOR LIGHT
FIGURE 36
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REMOVAL OF TONNEAU COVER
FIGURE 37
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 screwdriver &
adjusting the spring clip on the strut as shown. Refer to figure #38.
NOTE: Do not remove the spring clip. Only a small amount of levering is required to detach.
2
4
3 DRIVER’S SIDE ONLY
UNDERSIDE OF
TONNEAU COVER
GAS
STRUT
1
5
WIRING
HARNESS
GAS
STRUT TOP
4-WAY
CONNECTORS
GAS
STRUT
BALL STRUT
SCREW
GAS STRUT BOTTOM
FIGURE 38
2. Remove hinge pins and remove the Tonneau Cover as shown. Refer to figure #39.
1 RIGHT HAND SHOWN
HINGE
PIN
2 RIGHT HAND SHOWN
3
HINGE
PIN
FIGURE 39
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REPLACEMENT OF TONNEAU COVER
FIGURE 40
1. Fit Tonneau Cover and secure hinges with hinge pins as shown. Refer to figure #41.
1
2 RIGHT HAND SHOWN
3 RIGHT HAND SHOWN
HINGE
PIN
HINGE
PIN
“CLICK”
FIGURE 41
2. Attach gas struts by clipping into place. Ensure the narrow end 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. Refer to figure #42.
NOTE: Refer to Diagram #35: Ensure the gas strut switch works correctly and adjust if necessary.
LARGE
END
1
2 DRIVER’S SIDE ONLY
3
UNDERSIDE OF
TONNEAU COVER
GAS
STRUT
BALL STRUT
SCREW
NARROW
END
WIRING
HARNESS
GAS
STRUT TOP
GAS STRUT BOTTOM
4-WAY
CONNECTORS
FIGURE 42
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HOLDEN VE UTE 2007
1PC HARD TONNEAU COVER
KEY IDENTIFICATION CODE
X
XX
XX
Please write your key identification code in the boxes above and retain.
Replacement keys can be purchased from your local Holden dealer.
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