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Toyota HILUX 'A' DECK, Fitting Instructions Manual

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Toyota HILUX 'A' DECK Fitting Instructions Manual Download Page 12

22.  Ensure the inside of the foot caps is clean. Apply a 6mm bead of non acetic silicon (not supplied) around the inside 
surface of the foot cups. Remove tape liner from foam gasket and apply to base of foot cups as shown, Ensure LH and RH 
gaskets match up with foot cup cut-out. Re-attach foot cups to the sports bar feet to ensure silicon seals foot cups. Ensure 
silicon does not protrude above foot cups. 

See Dia #22

.

24. Flip the sports bar over and place on a piece of cardboard to avoid damage. Fit the infill panel to the sports bar, secure 
the sports bar foot brackets loosely using previously removed hardware. LHS shown, repeat for RHS. 

See Dia #24

.

LHS SHOWN

FOOT CUP

FOOT CUP

SPORTS BAR

 BOLTS

LHS SHOWN

DO NOT TIGHTEN FULLY

SILICON INSIDE

SILICON INSIDE

Page 12 of 34

Accessory Part No. PZQ70-89870

ISSUE 4: 09/10/18

Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870  

TC0403c

23. Fit the sports' bar brackets into the infill panels as shown. NOTE: due to the shape of the front bracket, carefully 
install the bracket on an angle to avoid damaging the paint.  

See Dia #23

. 

Diagram #23

Diagram #22

Diagram #24

26

27

INSERT AND SLIDE UPWARDS

T50

Summary of Contents for HILUX 'A' DECK

Page 1: ...ges is required use only Graphite Powder DO NOT use any other lubricants or oils HILUX A DECK With Sports Bar September 2016 Production Onwards HARD TONNEAU COVER FITTING INSTRUCTIONS TC0403c Accessory Part No PZQ70 89870 ISSUE 4 09 10 18 Check that all work practices comply with safety standards Please wear appropriate clothing and use safety equipment Safety Notes Read through the fitting instru...

Page 2: ...S S Spring Washer WASH0103 Qty 4 M8 Nut NUTS0217 Qty 2 M6 Nylock NUTS0016 Qty 8 M6 S S Hex Nut NUTS0161 Qty 8 M8x50 Hex Head Bolt SCRW0789 Qty 2 M8x20 Hex Head Bolt SCRW0665 Qty 2 M6x20 Hex Head Bolt SCRW0028 Qty 8 M8 Shoulder Bolt SCRW0897 Qty 8 Rubber Thread Cap MISC2532 Qty 4 1 2 3 4 5 6 7 13 8 10 9 11 12 14 15 20 16 17 18 22 23 24 26 27 29 30 31 32 33 34 35 36 38 39 37 40 41 42 43 44 Fitting I...

Page 3: ... s Flat Head Screwdriver Hard Tonneau Cover A Deck Accessory Part No PZQ70 89870 Page 3 of 34 TC0403c Accessory Part No PZQ70 89870 ISSUE 4 09 10 18 Relay Harness x1 locking variant only A B D Extension Patch x1 C Power Harness x1 1 Way Female Connector x2 locking variant only E 6 Way Female Connector x1 6 Way Male Connector x1 locking variant only F Scotch Lock Housing x1 G H J Mini Blade Fuse x1...

Page 4: ...TART STEP 1 SPORTS BAR REMOVAL IF APPLICABLE FINISH STEP 6 STEP 20 STEP 2 STEP 5 STEP 21 STEP 35 STEP 36 STEP 67 PAGE 29 PAGE 28 TUB PREP FOR HTC INSTALL HTC INSTALL AND ADJUSTMENT HTC ADJUSTMENT LOCK ADJUSTMENT WIRING HARNESS INSTALLATION UTELINER MODIFICATIONS TO FIT HTC IF APPLICABLE DUST DEFENCE KIT INSTALLATION ...

Page 5: ...to removing the sports bar assembly from the vehicle tape the front nut plate for the forward facing bolts securely to the tub between the tub and the cabin as access is restricted after the sports bar assembly is fitted to the tub Remove sports bar from the vehicle Retain the hardware for reinstallation See Dia 1 REMOVE HARDWARE IN 12 LOCATIONS 3 Remove the uteliner See Dia 3 UTELINER Diagram 1 2...

Page 6: ...35mm HOLE PAPER TEMPLATE HOLE FOR ELECTRICAL HARNESS IN TUB Ø35mm 5 Cut out the paper template from page 34 of this fitting instruction Place the template in the front left corner of the uteliner as shown Mark and drill 35mm hole in the uteliner for the lamp harness See Dia 5 6 Cut out and adhere the supplied Template 1 from page 33 to the LHS front inner tub panel area 2 using tape Mark Ø3mm on t...

Page 7: ...ONT TUB PANEL FRONT MASKING TAPE 1368mm 1298mm 910mm 824mm 789mm 28mm 28mm SIDE VIEW 2 3 4 C B B A A 1 TUB Ø5 5mm 4 8 Place the header bar centrally on the front tub rail Mark the 7 holes position from the header bar Use a hole puncher to punch through the foam tape on the top four holes Drill the 7 pre marked holes with 5 5mm drill bit Apply Rust Inhibitor to all drilled holes See Dia 8 7 Using a...

Page 8: ...over A Deck Accessory Part No PZQ70 89870 TC0403c Page 8 of 34 Accessory Part No PZQ70 89870 ISSUE 4 09 10 18 11 Secure the Header Bar to the tub with 7 rivets 17 See Dia 11 4 17 17 Diagram 10 Diagram 11 SILICONE BEAD SILICONE BEAD 12 To help prevent water ingress into the tub apply a bead of silicon non acetic along both gaps between the Header Bar edge and side panels Use a soapy water solution ...

Page 9: ...on Rubber seal must be positioned correctly as shown Follow the diagram above See Dia 15 5 5 4 4 13 To prevent water ingress apply a bead of silicon non acetic along the edge of both the LHS RHS inspection panel inside the tub as shown See Dia 13 FRONT OF THE VEHICLE COMPLETE THIS STEP ONLY IF VEHICLE IS FITTED WITH A UTELINER UTELINER Hard Tonneau Cover A Deck Accessory Part No PZQ70 89870 TC0403...

Page 10: ...ram 18 C C 17 Install the jacking bolts and nuts to the jacking brackets as shown Attach the jacking bracket 22 to position C using M8 bolts flat washers and M8 nuts Torque 8Nm Repeat for RHS See Dia 17 B B SIDE RAIL SECTION VIEW 35 19 22 24 23 23 24 31 29 30 18 33 14 21 TORQUE 8Nm TORQUE 8Nm FRONT OF THE VEHICLE 40 40 41 41 42 42 Diagram 16 SECTION VIEW 16 Attach the Pin Switch Contact Plate 42 t...

Page 11: ...ets and foot cups from the sports bar Retain all the hardware Note Run M8 tap through sports bar mounting brackets See Dia 21 Hard Tonneau Cover A Deck Accessory Part No PZQ70 89870 TC0403c Page 11 of 34 Accessory Part No PZQ70 89870 ISSUE 4 09 10 18 Diagram 20 A A 19 Align lock striker bracket 10 to the holes position A on the LHS NOTE Striker side marked B must attach to the tub as shown Place t...

Page 12: ...cardboard to avoid damage Fit the infill panel to the sports bar secure the sports bar foot brackets loosely using previously removed hardware LHS shown repeat for RHS See Dia 24 LHS SHOWN FOOT CUP FOOT CUP SPORTS BAR BOLTS LHS SHOWN DO NOT TIGHTEN FULLY SILICON INSIDE SILICON INSIDE Page 12 of 34 Accessory Part No PZQ70 89870 ISSUE 4 09 10 18 Hard Tonneau Cover A Deck Accessory Part No PZQ70 8987...

Page 13: ...rts bar to compress the foam seal on the foot cups and tighten all 12 attachment bolts to 35Nm in the following order 1 Front bracket forward facing bolts LH RH sides 2 Front bracket side facing bolts LH RH sides 3 Rear bracket side facing bolts LH RH sides See Dia 26 Page 13 of 34 Accessory Part No PZQ70 89870 ISSUE 4 09 10 18 Hard Tonneau Cover A Deck Accessory Part No PZQ70 89870 TC0403c ATTACH...

Page 14: ...34 Accessory Part No PZQ70 89870 ISSUE 4 09 10 18 Hard Tonneau Cover A Deck Accessory Part No PZQ70 89870 TC0403c Diagram 30 29 NOTE Two people are required to carry out fitment of the Tonneau Cover Carefully lift and fit the tonneau cover to the vehicle Ensure the hinges sit correctly in the header rail and that the tonneau flap header rail seals are sitting correctly check that they are not push...

Page 15: ...mation if necessary Note Set striker height at 35mm for starting point See Dia 33 Diagram 31 31 Attach the gas struts by clipping them into place as shown See Dia 31 ENSURE THE GAS STRUTS ARE ATTACHED AS PER THE PICTURES ON THE DIRECTIONS ARROWS MARKED ON THE STRUT BODY GAS STRUT GAS STRUT GAS STRUT BRACKET 13mm 13mm 35mm 32 Adjust jacking bolts 23 until infill panels are level with the main surfa...

Page 16: ...ESS SOLUTION BUBBLES 4 1 25 ISOPROPYL ALCOHOL 75 WATER APPLY CLEAR ABRASION TAPE ALIGN CLEAR ABRASION TAPE WITH TOP EDGE OF THE TAILGATE 2 35 Using a solution of 25 isopropyl alcohol and 75 water in a spray bottle not supplied Thoroughly spray along the top of the tailgate Remove liner from clear abrasion tape Working from one end with a 5mm overhang to the side of the tailgate place the clear abr...

Page 17: ...ttings Disconnect the negative terminal of the battery 1 in the engine bay See Dia 36 Diagram 36 37 At the front passenger side foot well area remove front passenger scuff plate remove the kick panel trim nut 2 and remove the kick panel 3 See Dia 37 Diagram 37 38 Unclip the glove box dampener 1 Remove LH retaining clip 2 by rotating anti clockwise Remove the glove box 3 Remove the driver s lower d...

Page 18: ...river unclip the connector secondary lock 1 Carefully remove the two Lock Unlock wires from the rear of the connector using a precision screw driver House the BLUE and GREEN lamp Relay Harness terminals 2 into the rear of the connector cavities in the positions shown BLUE WIRE UPPER CAVITY 3 GREEN WIRE LOWER CAVITY 4 Push the 20 way connector secondary lock 1 into place to retain terminals See Dia...

Page 19: ... Reconnect the 20 way hybrid junction connector to the vehicle See Dia 42 Diagram 42 43 Disconnect the 20 way junction connector 1 Scotch lock the Relay Harness terminal 2 to the 20 way junction connector Pin 20 3 RED wire terminal House the scotch lock terminal 2 with the supplied scotch lock housing 4 Reconnect the 20 way junction connector 1 Disconnect the 20 way junction connector 1 See Dia 43...

Page 20: ...Ensure the guide wire breaks the internal grommet seal Feed through until the Power Harness loop 5 reaches the grommet and is facing down Seal with silicon then cable tie 6 around the access point See Dia 46 Diagram 46 47 In the glove box cavity area retrieve the Power Harness 1 from the firewall grommet hole 2 House the five terminals 3 on the end of the Power Harness to the supplied connector 4 ...

Page 21: ...s shown See Dia 48 Diagram 48 49 If vehicle is NOT fitted with accessory fuse block go to Step 52 otherwise continue with Step 49 Remove the accessory fuse block cover 1 Disconnect the accessory fuse block 2 from its mounting bracket 3 Using side cutters remove and discard the cable tie 4 from the wire bundle Unclip and dislodge the fuse holder 5 See Dia 49 Diagram 49 50 Connect the Power Harness ...

Page 22: ...xtension Harness 1 way female connector 2 Route the fused RED wire 8mm ring terminal 1 to the positive battery terminal 3 Secure the fused RED wire 8mm ring terminal 1 to the back section of the battery positive terminal 3 using the existing nut 4 Secure Power Harness with supplied Cable Ties at every 200mm intervals See Dia 52 Diagram 52 53 Route the Power Harness 1 down into the engine bay towar...

Page 23: ...e of the LHS chassis rail Secure the Power Harness 1 to the chassis using Cable Ties 2 in the locations shown See Dia 55 Diagram 55 56 Following the LHS chassis frame route the remaining Power Harness branches 1 towards the LHS front of the tub Secure the Power Harness to the chassis using supplied Cable Ties 2 to the locations shown See Dia 56 Diagram 56 Front of vehicle 2 1 2 2 2 2 2 2 Front of ...

Page 24: ...am 57 58 Continue routing along the chassis rail towards the LH front tub panel Secure the Power Harness 1 to the chassis using supplied Cable Ties 2 to the locations shown See Dia 58 Diagram 58 59 Continue routing along the chassis rail towards the LH front tub panel Secure the Power Harness 1 to the chassis using supplied Cable Ties 2 to the locations shown See Dia 59 Diagram 59 Important Avoid ...

Page 25: ...ure the larger grommet Ø30mm is used See Dia 60 Diagram 60 61 From underneath the LHS front tub area clean the front tub panel 1 with the supplied Cleaning Pad and apply Primer Stick Allow to dry Secure the Power Harness to the front tub panel using the supplied Cable Tie Mount and Cable Tie 2 See Dia 61 Diagram 61 62 Underneath the vehicle locate the Power Harness 1 See Dia 62 Diagram 62 2 3 1 2 ...

Page 26: ...n the outside of the front tub panel in the area shown 1 Secure the Power Harness to the front section of the tub using supplied Cable Tie Mount and Cable Tie 2 See Dia 64 Diagram 64 65 Connect the 6 way male connector 1 to the front LH tonneau rail bracket 2 See Dia 65 Diagram 65 Important Ensure the Power Harness is kept clear of all sharp edges or moving parts 1 2 2 1 Front of vehicle Important...

Page 27: ...hinge operation of the Tonneau lid Important Reconnect the negative battery terminal Battery Post terminal to be torqued in between 2 9 and 7 8Nm Check the operation of the Tonneau cover ajar feedback system o Ensure the car is unlocked o Open the Tonneau cover window o Check that the door ajar indicator on the instrument cluster is on o Close the Tonneau cover o Check the door ajar indicator on t...

Page 28: ...hinges and latches at the positions shown 3 Ensure that the gas struts are NOT attached Adjust the position of the tonneau lid to the desired position or until the side and rear gaps are even ie A A and B B Tighten the hinge screws to 5Nm 4 Perform a latch position adjustment if necessary 5 Tighten remaining screws to 5Nm 6 Repeat steps 2 4 if further adjustment is required LOOSEN SCREWS LOOSEN SC...

Page 29: ...height is correct Test cycle the locks with the handle Open the tonneau lid and close the tailgate Close the tonneau lid and close the tonneau lid to check that the latches still engage release correctly with the striker hoops and that the height is correct If the striker height requires further adjustment repeat steps 2 4 until the latches engage release correctly striker height is correct Using ...

Page 30: ...3c Harness Circuit Diagram Front view of 20 way connector Front view of 6 way connector 1 3 2 4 5 6 Colour 1 BLACK BLUE GREEN GREY 2 3 4 5 6 RED RED BLACK Function GROUND LOCK UNLOCK DR SIGNAL 12V LAMP V Colour 1 BLACK BLUE GREEN GREY BLACK 2 3 4 5 6 RED RED BLACK Function GROUND LOCK UNLOCK DR SIGNAL 12V LAMP V 7 5A 7 5A ...

Page 31: ...n tonneau cover Disconnect the 6 way connector located in the front LH tonneau area Remove the tie clip from the bracket Detach gas strut 1 by inserting a small screwdriver and adjusting the spring clip 2 on the gas strut 1 Refer to figure 2 NOTE Do not remove the spring clip only a small amount of levering is required to detach 2 Remove hinge pins 1 and remove tonneau cover 2 Refer to figure 3 NO...

Page 32: ...THIS PAGE IS INTENTIONALLY LEFT BLANK ...

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