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TONNEAU COVER FITTING INSTRUCTIONS
Please read all the instructions before commencing your installation
CONTENTS
DESCRIPTION
TONNEAU COVER
ALUMINUIM ROPE TRACK
BAR BRACKETS
UNIVERSAL SUPPORT BAR KIT
SUPPORT BAR COVERALL
ALUMINIUM RIVETS
DOWELL
TRIANGLE BODY HOOK
BUTTONS
NOTE: Before you begin it is highly recommended that the vehicle is cleaned
*** Please complete your warranty registration which has been sent with your confirmation
order email the factory require completion of the warranty registration within 30 days of
ordering ***
UCDTY870R
TOYOTA HILUX WITH J DECK
1
QTY
TOOLS REQUIRED
x 1
DRILL
X 1
5/32" DRILL BIT or 4mm
X 4
TAPE MEASURE
X 2
FELT TIP PEN
X 2
POP RIVET GUN
X 18
CORROSION INHIBITOR
X 2
3mm ALLEN KEY
X 1
X 2
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Summary of Contents for COVERWORLD UCDTY870R
- Page 1 UCDTY870R TOYOTA HILUX WITH J DECK TONNEAU COVER FITTING INSTRUCTIONS Please read all the instructions before commencing your installation CONTENTS DESCRIPTION QTY TOOLS REQUIRED TONNEAU COVER x 1 DRILL ALUMINUIM ROPE TRACK X 1 5/32” DRILL BIT or 4mm BAR BRACKETS X 4 TAPE MEASURE UNIVERSAL SUPPORT BAR KIT X 2 FELT TIP PEN SUPPORT BAR COVERALL ...
- Page 2 STEP 1: ATTACH THE FRONT ALUMINIUM ROPE TRACK. The aluminium Rope Track should be located at the front of the tub as shown in the diagrams. The Rope Track should be facing upwards and the dowels sitting on the tub edge. Note: If you have a three piece Track extra dowels will be supplied to go between the pieces to help level as if it were one. Extra rivets will also be supplied (16 instead of 13) Using a : drill 6 holes through the Rope Track and into the front top of the 5/32” DRILL BIT or 4mm tub: one at 50mm from either edge, with the others evenly spaced between the outer two. Rivet the aluminium Rope Track into position. Note if you have a tub liner drill the holes towards the bottom of the flange and angle the drill down slightly to ensure the rivets go into the metal behind the plastic liner. 2 ...
- Page 3 STEP 2: FITTING SIDE BUTTONS AND REAR TRIANGLE HOOK Drill and rivet buttons 100mm down and 25mm forward of aluminium rope track (see Diagram) Using 2 rivets drill and rivet triangle body hook at the centre of tail gate above tailgate release handle (see Diagram). STEP 3: POSITION THE SUPPORT BAR To fit the bar brackets measure 700m from the rope track down the length of the inside of the tub, then down 5mm from the top edge of the tub (see Diagram) , or if you have 2 bar kits divid the tub length into thirds and position the brackets at these points. Drill and rivet bar bracket into place horizontally then repeat for other side of vehicle. If required apply corrosion inhibitor to the holes. STEP 4: ASSEMBLE AND FIT OF THE SUPPORT BAR CONTENTS OF EACH KIT 1 X HOLLOW BAR CENTERPIECE 2 X GRUB SCREWS 2 X SOLID BAR END PIECE 1 X BAR SOCK ASSEMBLY PROCEDURE FOR UNIVERSAL SUPPORT BAR 1. Insert solid bar pieces into either end of hollow tube. Adjust the bar so it fits between the bar bracket holders with the holes facing down (this is to ensure the grub screws do not rub against the tonneau cover), Finger tighten the grub screws into position then using a 3mm Allen key tighten a further ¼ turn (DO NOT OVERTIGHTEN AS THIS WILL STRIP THE GRUB SCREW THREAD). 2. Place the bar sock over the support bar this will stop the bar wearing against your tonneau cover. WARNING: FAILTURE TO FIT THE BAR SOCK OVER THE BAR WILL CAUSE UNNECESSARY WEAR OF YOUR TONNEAU COVER AND VOID THE WARRANTY. 3. Fit bar into bar brackets. ...
- Page 4 STEP 5: FITTING THE TONNEAU. Slide the front of the tonneau cover through the aluminium Rope Track section. Neatly spread the tonneau cover over the support bar, so it is centred and fully covers the tub, attach with cord. When carrying loads that are higher than the side of the vehicle tray, use the bungee and hook on the underside of the tonneau to secure the tonneau to the rails. CARING FOR YOUR TONNEAU. Apply bee’s wax or Dry‐Lube to the stitching a few times a year, as this will maintain the Tonneau’s waterproofing ability and prevent the stitching from degrading. Use a mild detergent and soft scrubbing bush to clean the tonneau cover. NEVER DRIVE WITHOUT TONNEAU SUPPORT BARS IN PLACE AS FLAPPING WILL CAUSE A UNDUE STRESS ON THE BUNJIS AND TONNEAU MATERIAL. . WARNING: TONNEAU IS NOT DESIGNED TO BE USED AS A LOAD RESTRAINT Thank you for purchasing an Australian made tonneau from COVERWORLD 4 ...