INSTALLATION INSTRUCTIONS

Accessory
INSTALLATION
INSTRUCTIONS
PARTS LIST
Application
Publications No.
All 28631-31200
TONNEAU COVER
P/N 08Z07-SJC-100
2006 RIDGELINE
Issue Date
OCT 2005
4 Rubber grommets
Tonneau cover
Left rail cap
Right rail cap
4 Brackets
Left rail
(four holes)
6 Clips
Right rail
(five holes)
Washer
Front bed panel rail
4 Plate nuts
2 Brackets A
8 Washer-bolts 6 x 14 mm
4 Washer-bolts 6 x 20 mm
Bracket B
2 Brackets C
6 Rubber guides
Left seal
2 Brackets D
Right seal
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
All 28631-31200 (0510)
08Z07-SJC-1000-91
1 of 13
3 Collars
TOOLS AND SUPPLIES REQUIRED
Phillips screwdriver
Flat-tip screwdriver
Ratchet
3 Long flange bolts
10 mm Socket
T40, T50 Torx wrench
Drill
3 mm, 6 mm, and 10 mm Bit
Vari bit
15 mm and 25 mm Holesaw
16 Short flange bolts
Hacksaw blade
Utility knife
File
Eye protection (face shield, safety goggles, etc.)
8 Bumper bolts
Scale
Isopropyl alcohol
Shop towel
Rubber mallet
7 Clips
Measure
Hard plastic plate (approx. 50 mm x 80 mm x 1 mm)
Felt-tip pen
KTC trim tool set (SOJAT P201H)
Circle grommet
6 Ellipse grommets
INSTALLATION
Customer Information: The information in this
installation instruction is intended for use only by
skilled technicians who have the proper tools,
equipment, and training to correctly and safely add
equipment to your vehicle. These procedures
should not be attempted by “do-it-yourselfers.”
NOTE: Be careful not to damage the body finish.
Lock bracket
2 Keys
2 Cushion tapes
2 of 13
All 28631-31200 (0510)
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
1.
Make sure you have the anti-theft code for the
radio, then write down the radio station presets.
2.
Disconnect the negative cable from the battery.
3.
Remove the left front upper tie-down hook (two
torx bolts). Remove the right front upper tie-down
hook (two torx bolts).
5.
While wearing eye protection, enlarge the three
upper holes in the front bed panel using a 1 in.
(25 mm) step drill. Remove all burrs from the
edges of the holes with a file.
STEP DRILL
Expand the holes
to 1 in. (25 mm).
FRONT BED
PANEL
LEFT FRONT UPPER
TIE-DOWN HOOK
TORX
BOLT
(T50)
UPPER HOLE
Top edge
6.
4610041H
4.
Remove the front bed panel (six torx bolts).
4611010H
While wearing eye protection, drill a 3 mm hole
through eight marked locations on the inside of the
front bed panel.
DRILL (3 mm drill bit)
MARKS (8)
TORX
BOLTS (6)
FRONT BED
PANEL
3929032H
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
All 28631-31200 (0510)
FRONT BED
PANEL
(Inside)
3920131T
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7.
While wearing eye protection, use a 15 mm hole
saw to enlarge the eight holes you drilled in step 6.
Work from the outer surface of the front bed panel.
Remove all burrs from the edges of the holes with
a file.
10. Remove the left bed rail trim.
FRONT BED PANEL
(Outer Surface)
•
Remove the screw cover (four retaining clips).
•
Remove the one self-tapping screw from the
rear of the bed rail trim.
•
Slide the bed rail trim back to release the six
clips, and remove the bed rail trim.
•
Remove the right bed rail trim the same way.
RETAINING
CLIPS (4)
SCREW
COVER
CLIPS (6)
15 mm
HOLESAW
HACKSAW
BLADE
HOLES
made in step 6
MARK
SELFTAPPING
SCREW
3920141T
LEFT BED
RAIL TRIM
8.
Using a hacksaw blade, cut the front bed panel
between the marks on both sides.
9.
Install the rubber grommets into the holes you
just made.
3926071H
FRONT BED PANEL
11. Remove the rear roof trim.
•
Remove the rear roof trim bolt covers (three
retaining clips for each cover). Remove the two
roof trim nuts.
BOLT COVER
RETAINING
CLIPS (3)
NUT
REAR
ROOF
TRIM
FRONT
BED PANEL
RUBBER
GROMMETS (4)
3920151T
RETAINING
CLIPS (3)
NUT
4D19051H
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All 28631-31200 (0510)
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
•
Using the KTC trim tool, carefully pry up the
front of the trim to release the three front clips.
Start with the left clip, and work your way to
the right clip.
•
Gently lift the front of the trim to release the
four remaining clips.
12. Remove the light first (one screw, one connector),
then remove the left C-pillar outer trim by sliding it
rearward, and disconnect the vehicle connector.
Remove the clips from the body, and reinstall the
clips to the C-pillar outer trim.
C-PILLAR OUTER
TRIM STAY
CLIPS (3)
CLIPS (3)
KTC TRIM
TOOL
VEHICLE
CONNECTOR
CLIPS (7)
RIGHT CLIP
(Finish here.)
LEFT CLIP
(Start here.)
LEFT C-PILLAR
OUTER TRIM
REAR CLIPS (4)
4D19062H
•
Gently pull up the rear roof trim to release the
two hooks.
•
Remove the antenna grommet and the highmount brake light grommet from the roof
panel, disconnect the vehicle connectors, and
remove the roof trim.
4611021H
CONNECTOR
13. Remove the left lower light (one self-tapping
screw, pull the left lower light out toward you, and
unplug the vehicle connecter).
LEFT LOWER
LIGHT
SELF-TAPPING
SCREW
HOOKS (2)
VEHICLE
CONNECTER
REAR
ROOF
TRIM
VEHICLE
CONNECTOR
TORX
BOLT
(T50)
LEFT REAR
TIE-DOWN HOOK
ANTENNA
GROMMET
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
3926062H
4804024H
14. Remove the left rear tie-down hook (two torx
bolts).
All 28631-31200 (0510)
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15. Remove the left side bed panel (six torx bolts).
18. While wearing eye protection, use a 15 mm hole
saw to enlarge the eight holes you drilled in step
17. Work from the front surface of the left bed
panel. Remove all burrs from the edges of the
holes with a file.
LEFT SIDE
BED PANEL
The holes you made in the upper part of the left
bed panel are to drain water.
15 mm HOLESAW
TORX
BOLTS (6)
(T40)
3926021H
16. Remove the spare tire tie-down clip on the right
side panel, then repeat steps 12 thru 15 to remove
the right side bed panel.
HOLES made
in step 17
17. While wearing eye protection, drill a 3 mm hole
through each of the eight marked locations.
LEFT BED PANEL
(Front Surface)
DRILL (3 mm bit)
3920171T
19. Repeat steps 17 and 18 to mark and drill the right
bed panel.
20. To prevent damage, wrap electrical tape around
the drill bit at a point 30 mm away from the tip.
While wearing eye protection, drill a 10 mm hole
through each of the three locations on the left side
of the lower bed panel. Repeat on the right side.
LEFT BED PANEL
(Inside)
NOTE: The holes you made are to drain water.
ELECTRICAL
TAPE
MARKS (8)
DRILL
(10 mm bit)
30 mm
3920161T
DRILL BIT
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All 28631-31200 (0510)
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
21. Using isopropyl alcohol on a shop towel, clean the
left bed panel where the left seal will attach.
22. Remove the adhesive backing from the left seal,
and attach it to the left bed panel as shown.
25. Position bracket A, C and D on the right vehicle
panel, and install them with two short flange bolts
for each bracket.
BRACKET A
BRACKET C
BRACKET D
LEFT BED PANEL
LEFT SEAL
SHORT FLANGE
BOLTS (6)
3930031H
26. Reinstall the left and right bed panels.
27. Reinstall the right and left C-pillar outer trims.
ADHESIVE
BACKING
28. Remove and discard the grommets from the roof
panel, and install the ellipse grommets and one
circle grommet to the roof panel.
3920180T
23. Install the right seal to the right side bed panel the
same way.
GROMMET
(Discard.)
CIRCLE
GROMMET
24. Position bracket A, B, C and D on the left vehicle
panel, and install them with two short flange bolts
for each bracket.
ELLIPSE
GROMMETS (6)
BRACKET A
BRACKET B
BRACKET C
SHORT FLANGE
BOLTS (8)
GROMMET (6)
(Discard.)
BRACKET D
3930021H
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
All 28631-31200 (0510)
4D20510K
7 of 13
29. On the back of the rear roof trim, remove and
discard the clips from the rear roof trim, and install
the seven clips.
REAR ROOF
TRIM
32. Using isopropyl alcohol on a shop towel, clean the
left rail where the water stoppers will attach.
33. Get the water stoppers and clips, remove the
adhesive backings from the three water stoppers,
and attach them to the left rail. Attach the three
clips into the holes in the water stoppers.
ADHESIVE
BACKING
CLIPS (7)
CLIPS (3)
WATER
STOPPERS (3)
CLIPS (7)
(Discard.)
LEFT RAIL
4D20501K
30. Reinstall the rear roof trim.
3920200T
31. Install the left and right rail caps to the front bed
panel rail.
34. Install the water stoppers to the right rail the same
way.
35. Place the front bed panel in position, and loosely
install the three bottom bolts.
LEFT RAIL CAP
FRONT BED
PANEL RAIL
FRONT BED
PANEL
RIGHT RAIL CAP
3920190T
3930042H
TORX BOLT
(Reused.)
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All 28631-31200 (0510)
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
36. Check that the seal you attached in step 21 is not
twisted or collapsed. If it is, raise it by inserting a
scale or small screw driver.
38. Slide or push (by hitting with a rubber hammer) the
left and right rail caps until they contact the bed
panel.
LEFT AND RIGHT
BED PANEL
SEAL FRONT BED
PANEL
LEFT RAIL
CAP
FRONT BED
PANEL RAIL
RIGHT RAIL
CAP
LEFT
SEAL FRONT
and
BED
RIGHT
PANEL
BED
PANEL
3920211T
3920231T
37. Position three collars, (one washer with the center
collar) and the front bed panel rail against the front
bed panel, and install three long flange bolts.
Tighten the flange bolts and the torx bolts installed
in step 34.
39. Position the left rail to the left bed panel, and
install four bumper bolts. Install the right rail the
same way.
NOTE: Make sure the rail fits into the rail cap.
WASHER
LEFT RAIL
CAP
COLLARS (3)
LEFT RAIL
3930062H
FRONT BED
PANEL RAIL
LONG FLANGE
BOLTS (3)
BUMPER BOLT
3920301T
LEFT RAIL
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
All 28631-31200 (0510)
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40. Insert two plate nuts into the slots in the left and
right rails.
LEFT RAIL
42. Using a felt-tip pen, mark the tailgate panel at the
center of the torx bolt located at the right end of
the tailgate panel.
MARK
FELT-TIP PEN
TAILGATE
PANEL
TORX
BOLT
PLATE
NUTS (2)
LEFT
RAIL
PLATE NUT
3920241T
41. Remove the tailgate trim:
•
Remove the four screws and release the one
end clip on each side.
•
Using a rubber mallet, sharply strike the left
edge of the tailgate trim to slide the trim to the
right and release the 16 clips from the trim.
•
Remove the 16 clips from the tailgate and
reinstall the 16 clips to the tailgate trim in the
direction shown.
3920330T
43. Install the tailgate trim on the tailgate panel. Using
a felt-tip pen, mark the tailgate trim where it aligns
with the mark you just made on the tailgate panel.
CLIPS (16)
TAILGATE
PANEL
FELT-TIP PEN
SELFTAPPING
SCREWS (4)
TAILGATE
TRIM
3920340T
RUBBER
MALLET
CLIPS (2)
TAILGATE TRIM
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4605081T
All 28631-31200 (0510)
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
44. Remove the tailgate trim. Measure the tailgate
trim from the marked point to the dimensions
shown, and cut out the tailgate trim.
48. Fold the tonneau cover, and attach it to the bed
rail. Check that the projection of the bed rail sets
in the concave section of the tonneau cover
securely. Note that the tonneau cover is heavy.
Work with an assistant when you install the
tonneau cover.
10 mm
23 mm
MARKED
POINT
29 mm
TONNEAU
COVER
29 mm
TAILGATE
TRIM
UTILITY
KNIFE
push
TONNEAU
COVER
3920350T
3920253T
45. Remove the torx bolt from the right end of the
tailgate panel. Install the lock bracket on the
tailgate panel with the TORX bolt you just
removed.
CONCAVE
BED RAIL
PROJECTION
TAILGATE PANEL
LOCK
BRACKET
3920360T
TORX BOLT
(Reuse.)
46. Reinstall the tailgate trim.
47. Reinstall the tie down hooks.
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
All 28631-31200 (0510)
11 of 13
49. Install the four brackets to the four plate nuts with
the 6 x 20 mm washer-bolts. Do not tighten them
yet.
•
Install the left brackets in front of the brackets
on the underside of the tonneau cover. Install the
right brackets behind the brackets on the
underside of the tonneau cover.
50. Push the tonneau cover forward. Slide the
brackets and align the holes in the bracket with
the holes in the tonneau cover brackets, then
install the 6 x 14 mm washer-bolts.
6 x 14 mm
WASHER-BOLT
FRONT
RIGHT SIDE
TONNEAU COVER
BRACKET
FRONT
BRACKET
RIGHT SIDE TONNEAU
LEFT SIDE TONNEAU
PLATE COVER BRACKET
COVER BRACKET
NUT
BRACKET
FRONT
FRONT
BRACKET
6 x 20 mm
WASHERBOLT
BRACKET
6 x 20 mm
WASHERBOLT
PLATE
NUT
6 x 14 mm
WASHERBOLT
LEFT SIDE
TONNEAU
COVER
BRACKET
FRONT SIDE
TONNEAU COVER
3920272T
3920262T
FRONT SIDE
TONNEAU
COVER
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All 28631-31200 (0510)
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
51. Unfold the tonneau cover. Open and close the
tailgate 3 to 4 times until the tonneau cover fits
properly. Then tighten the 6 x 20 mm washer-bolts.
FRONT
53. Lock the rear of the tonneau cover by turning the
two knobs 90 degrees.
KNOBS (2)
Turn 90 degrees to lock.
FRONT
6 x 20 mm
WASHERBOLT
6 x 20 mm
WASHER-BOLT
TONNEAU
COVER
REAR
PANEL
TONNEAU COVER
FRONT PANEL 3920321T
TAILGATE
52. Attach cushion tape to both hinges. Attach the
tape to the front half of the hinge so that it
cushions the rear half of the hinge as shown.
CUSHION
TAPE
HINGE
REAR SIDE
TONNEAU COVER
3920293T
54. Turn the two knobs to unlock the tonneau cover.
55. Reconnect the negative cable to the battery.
56. Reset the clock, and reset the radio station
presets.
NOTE: Whenever the battery is disconnected, the
driver’s window AUTO function is disabled.
FRONT SIDE
TONNEAU COVER
CUSHION
TAPE
57. Start the engine. Push down on the driver’s
window switch until the window is fully open.
58. Check that the cargo lights are working.
FRONT
FRONT
59. Pull up on the driver’s window switch to close the
window completely, then hold the switch for
2 seconds or more.
REAR SIDE
TONNEAU COVER
60. Lower and raise the window to check the operation
of the driver's window AUTO function.
61. Give the keys to your customer.
REAR SIDE
TONNEAU
COVER
© 2005 American Honda Motor Co., Inc. - All Rights Reserved.
FRONT
SIDE
TONNEAU
COVER
3920400T
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