EGR EGR-3PVE-COLOUR Installation Instructions Manual Download Page 6 | Manualshive

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EGR EGR-3PVE-COLOUR Installation Instructions Manual Download Page 6

TC0123b

page 6 of 28

3PC TONNEAU COVER WITH SPORTS BAR & REMOTE LOCKING

21/05/08

4. 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.

See Dia #4

.

Diagram #4

10mm

DRILL TEMPLATE

Ø5mm

4

5

Ø10mm

6

7

FIT

1

REMOVE

3

2

MARK, CENTRE PUNCH,

DRILL Ø5mm THEN Ø10mm HOLES

& APPLY RUST INHIBITOR

DRILL TEMPLATE

HINGE

BASE

PLATE

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

5. Attach the hex head bolt, wizlock nut and rubber washer to a nut insert as shown. Insert nut insert assembly through drilled hole in
header rail. While holding the wizlock nut in place with a 13mm spanner, tighten the bolt until the nut insert collapses completely in the
drilled hole (the nut insert is collapsed when the bolt starts to become tight, at approx torque 6Nm). Remove bolt, wizlock nut and
rubber washer. Repeat process for the remaining seven (7) drilled holes.

See Dia #5

.

NOTE: Replace rubber washer during each installation.

Diagram #5

NUT

INSERT

RUBBER

WASHER

WIZLOCK

NUT

NUT

INSERT

HEX

HEAD BOLT

REMOVE

HEX HEAD

BOLT

REMOVE

WIZLOCK NUT

REMOVE
RUBBER
WASHER

1

2

3

4

NUT INSERT

ASSEMBLY

HEADER RAIL

13MM

SPANNER

(HOLD NUT)

WIZLOCK NUT

ROTATE

BOLT

UNTIL TIGHT

(WITH 10MM

SOCKET)

HEADER RAIL

13mm

10mm

10mm

10mm

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Summary of Contents for EGR-3PVE-COLOUR

Page 1: ...25 26 27 28 29 30 31 32 33 34 35 36 M6x30mm Screws M6 Flat Washers M6 Spring Washers Pop Rivets Gas Struts Clear Protection Pads Flat Washers 14mm x 5 5mm Nut Inserts 4 Spare Hex Head Bolt Wizlock Nu...

Page 2: ...21 05 08 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 AUTOMOTIVE SURFACE CLEANER IMPREGNATED WITH 70 ISOPROPYL ALCOHOL For use in cleaning painte...

Page 3: ...ED LED Gasket attached to LED Wiring Connector Male Wiring Adapter Loom M4x30mm Screws Component Name Qty Item 12 13 14 15 16 17 18 19 20 21 22 M4 Internal Tooth Washers Foot Gasket Left Hand Front Fo...

Page 4: ...RTANT 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 car...

Page 5: ...with an LED brake light at the top of the rear window proceed to Diagram 2 Otherwise proceed to Diagram 3 BLACK DECAL LED BRAKE LIGHT 3 Using a non permanent marker find and mark the centre point of t...

Page 6: ...D 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 SYST...

Page 7: ...3PC TONNEAU COVER WITH SPORTS BAR REMOTE LOCKING 21 05 08 COUNTERSUNK SELF TAPPING SCREWS HINGE BASE PLATE TORQUE 3Nm TOP TUBE LED WIRING LED M4 INTERNAL TOOTH WASHERS M4x30 SCREWS TORQUE 2Nm LED GAS...

Page 8: ...Ensure the warning label is orientated correctly If wording is upside down flip bar 180 Diagram 9 11 Note the protective lining on back of Sports Bar foot gaskets Trial fit the gaskets to the Sports...

Page 9: ...Bar foot as shown ensuring the holes in the Sports Bar feet remain accessible Repeat process for the other side of the vehicle See Dia 12 Diagram 12 13 Remove the three 3 tie down brackets on the rig...

Page 10: ...s both the wiring adapter loom and the wiring harness As only the wiring harness is required for this installation do not use the wiring adapter loom See Dia 16 Diagram 16 TC0123b page 10 of 28 3PC TO...

Page 11: ...COVER WITH SPORTS BAR REMOTE LOCKING 21 05 08 19 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 ear...

Page 12: ...ide rail Repeat process for the other side of the vehicle See Dia 22 Diagram 22 RIGHT HAND SHOWN FRONT VIEW JACKING BRACKET LINER FIXTURE LINER FIXTURE x2 JACKING BRACKET SIDE RAIL MARK HOLES ALIGN RI...

Page 13: ...GHT HAND CORNER PIECE SPORTS BAR M6x30mm SCREWS M6 SPRING WASHER M6 FLAT WASHER 1 DRAW LINE AGAINST EDGE CLEAR PROTECTION PAD RIGHT HAND SHOWN RIGHT HAND SHOWN 26 Remove the Sports Bar from the vehicl...

Page 14: ...ping plates with tapped holes into the side rail and locate centrally over the top of the previously drilled holes Repeat process for the other side of the vehicle See Dia 29 Diagram 29 28 Using a tor...

Page 15: ...THE CORRECT LOCATION OF THE RED BRAKE SIGNAL WIRE TO ENSURE THEY MATCH WHEN THE WIRES ARE INSERTED INTO THE MALE CONNECTOR IF THE WIRES DO NOT MATCH THE SPORTS BAR LED WILL NOT FUNCTION Diagram 31 1 L...

Page 16: ...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 35 Diagram 35 CLAMPIN...

Page 17: ...rews as shown Tighten to torque 3Nm Repeat the process for the other side of the vehicle See Dia 36 Diagram 36 38 Using a non permanent marker measure and mark on the inside of the side rail 500mm fro...

Page 18: ...side of the vehicle See Dia 41 Diagram 41 GAS STRUT BRACKET SELF TAPPING SCREW TORQUE 3Nm SELF TAPPING SCREW TORQUE 3Nm BALL STUD SCREW TORQUE 4Nm RIGHT HAND SHOWN 1 1 2 10mm 5mm RIGHT HAND SHOWN RIG...

Page 19: ...ng screws flat washers 14mm x 5 5mm and plastic spacers as shown DO NOT OVERTIGHTEN Repeat process for the other side of the vehicle See Dia 43 NOTE Plastic spacers fit inside the side rail panel betw...

Page 20: ...h gas strut with terminals to the driver s side of the vehicle Diagram 46 TC0123b page 20 of 28 3PC TONNEAU COVER WITH SPORTS BAR REMOTE LOCKING 21 05 08 NEXT STEP RE TORQUE 5Nm ENSURE CLEARANCE TO TU...

Page 21: ...mal movement when the tonneau is fully closed with the tailgate up in the closed position Diagram 48 1 INCORRECT INSPECT LATCH ENGAGEMENT CORRECT 2 ADJUST STRIKER BRACKET 3 IF THE HORIZONTAL POSITION...

Page 22: ...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 To...

Page 23: ...ly rust inhibitor to the drilled holes and then fasten the bracket into place using pop rivets as shown Repeat process for the other side of the vehicle See Dia 53 Diagram 53 10mm 5mm 1 2 RIGHT HAND S...

Page 24: ...LOCKED TONNEAU UNLOCKED GENTLY CLOSE TONNEAU LOOSEN SCREW OPEN TONNEAU COVER 57 Join the two 4 way connectors located at the front of the tub as shown Push the terminals behind the bedliner after they...

Page 25: ...lgate 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 lig...

Page 26: ...ruts 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...

Page 27: ...rness 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 56 Ensure...

Page 28: ...SPORTS BAR REMOTE LOCKING 21 05 08 KEY IDENTIFICATION CODE HOLDEN VE UTE 2007 3PC HARD TONNEAU COVER Please write your key identification code in the boxes above and retain Replacement keys can be pu...

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