Hilux (Double Cab) Hard tonneau cover Installation Instructions

Model year: 2015/04 Vehicle code: GUN1***-D***HW

Part number: PW3B1-0K008 Hard tonneau cover (grained finish) PW3B1-0K028 -** Hard tonneau cover (painted) PW3B1-0K102 Hard tonneau cover-side covers (grained finish) PW3B1-0K092-** Hard tonneau cover-side covers (painted)

Manual reference number: AIM 003 650-2

Ø 30mm

Ø 3mmØ 5mm

Ø 10mm

A:Sikkens® primer surfacer EP II

B:Sikkens® primer surfacer EP II Hardener

A:PRIMERB:ACTIVATOR

A:Standox® Etching Adhesion Primer 020 16167

B:Standox® Etching Adhesion Activator 020 16168

or

Teroson Multi-WAX Spray796107

Würth 0893 081-E/B

WAX

4 mm

Ø 10mmØ 12mmØ 13mmØ 17mm

Ø 12mmØ 13mmØ 17mm

3M 751

SikaflexRef.: 555

CLEANER / DEGREASER

10 mm

M8

MSDS

TDS

40°C

18°C

Manual reference number: AIM 003 650-2 2 of 28

Revision recordRev. No. Date Page Picture Update New Deleted steps

1 10.05.2016 All All X

2 20.06.2016 Various Various X

1x 1x

2x

2x

1x

4x6x

PW3B1-0K008 Hard tonneau cover (grained finish)PW3B1-0K028-** Hard tonneau cover (painted)

PW3B1-0K102 Hard tonneau cover-side covers (grained finish)PW3B1-0K092-** Hard tonneau cover-side covers (painted)

J AF

Q

M

1xL

X Y 4x Z 30x AA 26x AB 20x AC 4x6x AD4x 4xX

4xK

4xAE

8x N

2x R 4x S 2x T 2x U 4x V 4x W

2x O 2x P 1x AF 1x AG

M6

M8

M6 M6 M6

LH RH

2x

M8X20 M8 M8 M8 M8 M8 OD25 ID8.3

M8X35

Manual reference number: AIM 003 650-2 3 of 28

PROTECTION

x2

M8

AF

2

3

3

X

X

1 CLEANER / DEGREASER

Manual reference number: AIM 003 650-2 4 of 28

3

1

2

N

LAF

3

1

2x

10mm

2

0 mm

2

A A

1

Manual reference number: AIM 003 650-2 5 of 28

5

4

N

X

U

V

L

L

2x

Ø 3 mmØ 5 mm

3 10 mm 2

6x

Ø 3 mmØ 5 mm

5 10 mm 4

1

2x

1 2

6x

Manual reference number: AIM 003 650-2 6 of 28

7

6

L

WAX

1 4

6 7

3mm

30 min.

21°C

8

21°C

3

10 min.

MAX 15 min.1 6

2

3x 3x

2x

5

3mmCLEANER / DEGREASER

Manual reference number: AIM 003 650-2 7 of 28

8

3

1

2x

10mm

2

8 Nm

S

Manual reference number: AIM 003 650-2 8 of 28

9

N

X

U L

V

30 mm 30 mm

x81

2

4

1

2

4

3

SikaflexRef.: 555

SikaflexRef.: 555

Manual reference number: AIM 003 650-2 9 of 28

10

M M

M M

M

2x 2x

2x

8x

LH = RH

1

2

1

1

2

3

Manual reference number: AIM 003 650-2 10 of 28

12

11

K

AG

AA

Z

AB

PAF

V

V

U

U

W

W

0 mm 0 mm

SEC. D-D SEC. C-C

SEC. B-B SEC. A-A

X=X

B

B

A

A

XX

C

C

D

D

Manual reference number: AIM 003 650-2 11 of 28

13

K

K

K

K

1

0 mm

x6

2

1(5) mm

Manual reference number: AIM 003 650-2 12 of 28

14

6x

Ø 3 mmØ 5 mm

Ø 10 mm

2 10 mm 1

WAX

3 67

8 930 min.

21°C

10

21°C

5

10 min.

MAX 15 min.2 8

4 3mm

3mm

CLEANER / DEGREASER

3

3

1

2

Manual reference number: AIM 003 650-2 13 of 28

16

15

LH = RH

10 mm

1

SikaflexRef.: 555

Ø6mm

CLEANER / DEGREASER

2

2

3

4

Manual reference number: AIM 003 650-2 14 of 28

17

6x

12 mm

1

2

Manual reference number: AIM 003 650-2 15 of 28

18

X Z AA

AC

Bedliner Bedliner

Ø 30mm

ALUMINIUM BEDLINERPW3B1-0K002

PW3B1-0K002 PW3B1-0K010

UNDER RAIL BEDLINERPW3B1-0K010

Ø 30mm

45°45°

> 0mm

45°

13mm 17mm

1 23

1

1 22

For full Installation instructions

http://www.toyota-tech.eu

Manual reference number: AIM 003 650-2 16 of 28

19

S

32

1

SikaflexRef.: 555Ø6mm

4

5

30mm

30mm

CLEANER / DEGREASER

Manual reference number: AIM 003 650-2 17 of 28

20

O

SikaflexRef.: 555

Ø6mm

Manual reference number: AIM 003 650-2 18 of 28

22

21

J

4x

4x

18 Nm13mm

SEC.

1

2

13mm

S

Manual reference number: AIM 003 650-2 19 of 28

24

23

J

L

XAA

Z

AB

X≠X

SEC. B-BSEC. A-A

X X

X=X

SEC. B-BSEC. A-A

X X

X

LH/RH

X=X

A A BB

Manual reference number: AIM 003 650-2 20 of 28

25

K

J

D D

E

E

F

F

CC SEC. D-D SEC. C-C

X=X

(X) mm(X) mm

SEC. E-E SEC. F-F

X=X

(X) mm(X) mm

X=XX=X

ClickClick

Click Click

Manual reference number: AIM 003 650-2 21 of 28

27

26

K

4x

12 mm

SEC. A-A

A

A

A

A

6x

18 Nm12mm

8x

18 Nm12mm

2x

8 Nm10mm

3 2

1

12mm

12mmLH = RH

S

S

S

Manual reference number: AIM 003 650-2 22 of 28

29

28

Q

AD Z Y

R

4x

4 mm

1 4x

4 mm6 Nm

3

2

CL CL

S

2

4x

12 Nm12mm

3

2

ClickCL

1

ClickCL

1

ClickCL

1

S

Manual reference number: AIM 003 650-2 23 of 28

30

31

31

Manual reference number: AIM 003 650-2 24 of 28

OWNER’S MANUAL

CABLE ADJUSTMENT

4x

4 mm

4

5

1 2

3

CL CL

LH=RH LH=RH

LH RH

10mm

Model year: 2015/04 Vehicle code:

GUN1***-D***HW

Part number:

PW3B1-0K008 Hard tonneau cover (grained

PW3B1-0K028- ** Hard tonneau cover (painted)PW3B1-0K102 Hard tonneau cover-side covers (grained finish) PW3B1-0K092- ** Hard tonneau cover-side covers (painted)

KG

CAUTION

4x

4 mm6 Nm

6

S

Manual reference number: AIM 003 650-2 25 of 28

Manual reference number: AIM 003 650-2 26 of 28

CHECK SHEET

VIN n°

Model / Year Hilux (Double Cab)2015/04

Hard tonneau cover

P/N = OK

Owner’s

manual

=A =B

LH = RH

SEC.

1

3

2

Serial NumberCLICK

Click

1

118Nm

4x6Nm

4x12Nm

4x

2

3

2 3 ...S BLH RH

A BA

8Nm2x4

4

Manual reference number: AIM 003 650-2 27 of 28

1 2

3

3

Installation Date: Stamp:Technician Name & Signature:

. . / . . / . . . .

LH = RH

LH = RH

3x

= OK

= OK = OK

1

2

1 2

2xClick

1xClick

Serial NumberCLICK

Click

1

18Nm

2x18Nm

6x18Nm

8x

2

3

2 3 ...

S

BLH RH

A BA

Manual reference number: AIM 003 650-2 28 of 28