CANOPY CP0015a INSTALLATION INSTRUCTIONS …

1 30/11/10 Page 1 of 24CP0015aPlace these INSTRUCTIONS in vehicle s glove box after INSTALLATION is completeClean CANOPY with a milddetergent and water not use abrasivecleaners or INSTRUCTIONS : INSTALLATION Time:1 Hour (Approximately)Without Bed Liner fitted1 Hour 45 minutes (Approximately)With Bed Liner fittedIMPORTANT! Read INSTRUCTIONS carefully before INSTALLATION . It is strongly recommended that INSTALLATION is conducted by an authorized dealer. This product must be installed exactly as specified in these INSTRUCTIONS . Failure to do so may result in improper fit and/or retention. Recommend INSTALLATION by 2 TOOL LIST - (Not Supplied in Kit) Loctite 277 thread locking liquid (IMPORTANT) Phillips Head Screwdriver Large Flat Blade Screwdriver Medium Adjustable Spanner Side Cutters Sockets 10, 12 & 13mm, Extension Bar and Driver Spanners 10, 12 & 13mm Silicon Dispensing Gun Non Acetic Silicon (Neutral Cure) Spray Bottle (25% isopropyl Alcohol & 75% Water) Spray Bottle Water Torque Wrench - 0-10Nm Angle Grinder (Medium Size) Non Permanent Marker Masking Tape Cleaning Cloths / Rags Steel Rule and Tape Measure Scissors (Sharp) Knife (Sharp) Squeegee Metal Primer 44mm Hole Saw & Drill File or Deburring Tool (Optional) 5mm Drill Bit (Optional) Rivet Gun for Stainless Steel RivetsTOYOTA HILUX Double Cab - SR / SR5(with & without Toyota Genuine Bed Liner)(February 2005 Production Onwards)

2 CANOPYINSTALLATION INSTRUCTIONSPLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES. IF FITTING CANOPY TO A J DECK VEHICLE (SR LEVEL),THEN ADDITIONAL SUPPLEMENTARY KIT PART No:- KIT-HLX05-JD WITH FITTING INSTRUCTIONS (CP0016) WILL BE CANOPY is designed to suit the Double Cab (4x2 & 4x4) SR & SR5 Bars MUST be removed & returned to Customer with all hardware components if Guards MUST be removed & Fitting Instruction where a Bed Liner is referred to, is based on -Toyota Genuine Over Rail Bed Liner Accessory Part No s. :-PZ053-0K003 (With Cabin Guard) PZ053-0K073 (Without Cabin Guard) 2 of 2430/11/10CP0015aTOYOTA HILUX - CANOPYPARTS CHECK SHEETTOYOTA HILUX CANOPYC anopyQty - 1 PARTS IN MAIN CARTONRail ExtrusionTub Stop(ALUM0038-8)Qty - 1 Fitting Kit(KIT031949)Qty - 1 Lock Keys(Attached toCanopy InternalRear Door Handle)Qty - 2 Kit - RailClamps(CNPY0007)Qty - 6 Clear AbrasionTape Roll48mm Wide(TAPE0611-1)Qty - 1 Tape (TAPE0386)Qty - 1 Screw M6x30 Hex Head SS304(SCRW0824)Qty - 4M6 Flat WasherOD.

3 19mm(WASH0169)Qty - 8M6 Nyloc NutSS304(NUTS0016)Qty - 4 Tape 4026 GHBWH12x1700mmx Roll(TAPE0615)Qty - 1 Bulb Seal 70mmCut Length(MISC2600-1)Qty - 2 Vehicle WiringPatch Harness(LOOM0016)Qty - 1 PARTS IN FITTING KIT (KIT031949)PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0016)Cable Ties(4) Long(2) ShortQty - 5 Adhesive TiePadQty - 1 Rivet SS304ST-ST 6-6(FAST0433)Qty - 8 Clear Tape Pad50x3mm AbrasionResistant(TAPE0011)Qty - 6 Front Tub SpacerExtrusion(ALUM0038-7)Qty - 1 RustInhibitorAlcohol Wipe(MISC0052)Qty - 4 AUTOMOTIVESURFACE CLEANERIMPREGNATED WITH 70% ISOPROPYL ALCOHOLFor use in cleaning painted metal,glass and other vehicle external use of properly after use. Rust InhibitorSatchel(MISC2776)Qty - 1 Primer Stick(MISC1365)Qty - 4 Vehicle WiringPatch Harness Kit(LOOM0016)Qty - 1 FittingInstruction(FIT- CP0015a )Qty - 1 FittingInstruction30/11/10 Page 3 of 24CP0015aTOYOTA HILUX - CANOPYIF A SPORTS BAR IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP A CABIN GUARD IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP THE VEHICLE HAS NO CABIN GUARD OR SPORTS BAR PLEASE PROCEED TO STEP the eight (8) bolts holding thesports bar feet to the tub as remove the sports bar from thevehicle and return to the customer withall hardware components.

4 (ref. diagram1). cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the CANOPY , and a piece betweenthe tub and cabin as a protection sheetwhile removing the cabin guard.(ref. diagram2). : 2 - PROTECT VEHICLE SURFACESA pply 200mm lengths of overlappingmasking tape to the top and side of thetub rail, up to and around the cabin guardas : Fit a 2mm thick steelplate as a sacrificial grinding plate (Notsupplied in kit), next to the cabin guardas shown, repeat process for the otherside of the vehicle. (ref. diagram3). : 3 - SECURE GRINDING PLATED iagram: 1 - REMOVE SPORTS BAR & HARDWAREFITTAPERECOMMENDEDFIT SACRIFICIALGRINDING PLATE12 REMOVEHARDWARE12 POSITIONCARDBOARDTUB AND CABINPROTECTION MATSCABIN GUARD5mm30/11/10 Page 4 of 24CP0015aTOYOTA HILUX - CANOPYS ecure the sacrificial grinding plate (notsupplied in kit) to the tub rail by coveringit with masking tape as process for the other side of thevehicle.

5 (ref. diagram4). a suitable protective timber boardof adequate thickness between thecardboard and cabin guard as : To avoid accidentaldamage to the vehicle, the timber boardMUST be used when ever cutting of thecabin guard is undertaken.(ref. diagram5).IMPORTANT: Ensure that the vehicle s(paint work, glass, ) is adequatelyprotected before removing the a medium sized angle grinder,partially cut through the rear and sidefaces of the LH outer cabin guard bar,taking care not to damage process for the RH side of thevehicle, ensuring the protective timberboard is repositioned behind the RH outercabin guard bar. (ref. diagram6). : 5 - PROTECT VEHICLE : 6 - REMOVAL OF CABIN GUARDD iagram: 4 - SECURE GRINDING PLATEPARTIALLY CUT THROUGHOUTER CABIN GUARD BARSSECURESACRIFICIAL GRINDINGPLATE WITH TAPEINSERTTIMBER BOARD30/11/10 Page 5 of 24CP0015aTOYOTA HILUX - CANOPYIMPORTANT: Ensure the protectivetimber board is repositioned behind each of the centre support bars a medium sized angle grinder,completely cut through the three (3)centre support bars at the base, flush tothe front tub rail, taking care not todamage vehicle surfaces.

6 (ref. diagram7). : Ensure the protectivetimber board is repositioned behind the outer cabin guard bars people are required to completethis step, one person will need tosupport the cabin guard and prevent itfrom damaging the vehicle while theother person finishes cutting throughthe cabin guard bars a medium sized angle grinder,completely cut through the LH and RHouter cabin guard bars, flush to thegrinding remove cabin guard fromvehicle and discard. (ref. diagram8).IMPORTANT: Ensure the protectivetimber board is repositioned to each bar location before care to prevent damage to a medium sized angle grinder,carefully cut away any remaining metalnot flush with the tub sacrificial grinding plates andall masking tape. (ref. diagram9). : 8 - REMOVAL OF CABIN : 9 - PREPARE VEHICLE SURFACESD iagram: 7 - REMOVAL OF CABIN GUARD12 INSERTTIMBER BOARDCOMPLETELY CUT THROUGHCENTRE SUPPORT BARS12 SUPPORTCABIN GUARDCOMPLETELY CUT THROUGHOUTER CABIN GUARD BARS12 GRINDAWAY ANY REMAININGMETAL NOT FLUSHWITH THE TUBREMOVEGRINDING PLATES& TAPE30/11/10 Page 6 of 24CP0015aTOYOTA HILUX - CANOPYU sing a file / de-burring tool, remove allburrs and sharp edges from cabin guardand tub rail surfaces previously cut withthe angle grinder.

7 (ref. diagram10). all timber boards and cardboardprotection mats from the cardboard tub floor protection matfor use later during the compressed air, completely blowout all metal filings, swarf in the tubfloor. (ref. diagram11).Using a suitable metal primer, paint overand completely cover all bare metalsurfaces previously cut and deburred.(ref. diagram16).Allow some paint drying time by readingthrough the next steps carefully andinstalling the vehicle wiring harnessthrough the vehicle cabin.(ref. diagram12). : 11 - CLEAN VEHICLE : 12 - PRIME VEHICLE SURFACESD iagram: 10 - PREPARE VEHICLE SURFACES1 REMOVETIMBER BOARDS& CARDBOARDPROTECTION MATSDEBURRALL SURFACES AROUNDCUT CABIN GUARD BARS230/11/10 Page 7 of 24CP0015aTOYOTA HILUX - CANOPYREMOVEBRAKE PEDALSWITCH CONNECTORSTEERINGCOLUMNBRAKEPEDALARM1 Thoroughly clean and dry installationareas (tub, rear of cabin and glass)as cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the CANOPY .

8 (ref. diagram13). : 13 - CLEAN & DRY INSTALLATION AREASPOSITIONCARDBOARD TUBPROTECTION MAT12 REMOVE AND RETAINFRONT SCUFF PLATEDRIVER S SIDE OFVEHICLE ONLYD iagram: 15 - REMOVE VEHICLE PARTSD iagram: 14 - REMOVE VEHICLE front driver s side and retain Front driver sside scuff and retain driver s side kick paneland hardware as shown.(ref. diagram5).Unplug the brake pedal switch maleconnector from the brake pedal switchas and retain the bolt securing aconnector to the vehicle as shown.(ref. diagram6).REMOVE & RETAINHARDWAREREMOVE & RETAINKICK PANEL312 REMOVE AND RETAIN BOLT2 ACCELERATORPEDAL30/11/10 Page 8 of 24CP0015aTOYOTA HILUX - CANOPYFEEDVEHICLEHARNESS BEHINDEXISTING LOOMSFITCABLE TIEVEHICLE WIRINGPATCH HARNESS2 CONNECTBRAKE PEDAL HARNESSCONNECTOR WITH VEHICLEHARNESS FEMALE CONNECTOR1 CONNECTVEHICLEHARNESS MALECONNECTORBACK INTO BRAKEPEDAL SWITCHFITBOLT, EYELETTERMINALAND CONNECTOR231 LIFT UPFLOOR COVERINGUNDER DRIVER S SEATREMOVE &DISCARDEXISTINGFLOORGROMMET3 FEEDVEHICLE HARNESS& PLUG INTO HOLEVIEW UNDERNEATH VEHICLE4 ENSUREPLUG IS FULLY SEATED5(OPTIONAL) APPLYSILICON AROUND GROMMET6 CHASSIS RAILD iagram: 18 - ROUTING VEHICLE HARNESSD iagram: 17 - CONNECT VEHICLE HARNESSD iagram.

9 16 - CONNECT VEHICLE the vehicle wiring patch harness(LOOM0016) from the hardware kit connectthe female connector to the brake pedalswitch male connector as the male connector from the vehicle wiring patch harness back intothe brake pedal switch as shown.(ref. diagram16).Route vehicle harness behind existingharness across to the kick panel and rundown to the front door scuff the previously removedbolt and connector (from step 15) with thevehicle wiring patch harness eyelet terminalunder the screw head and secure to thevehicle as : Be careful when tighteningto ensure wires are not stripped out ofthe eyelet one (1) short cable tie to secure thevehicle harness to existing harness asshown. Trim excess tie with side cutters.(ref. diagram17).Route vehicle harness along front doorscuff plate to the rear of the front up the front floor covering under thedriver s and discard the existing grommetin the floor.

10 Feed the vehicle harness downthrough the floor and fit the vehicleharness plug into the sheet : Check under the vehicle thatthe grommet is correctly located intothe sheet metal and fully seated toprevent water entering the vehicle.(Optional) We recommend to applynon-acetic silicon (neutral cure), to sealaround the grommet. (ref. diagram18).2 RUNHARNESS ALONGSCUFF PLATE1 NOT SUPPLIED30/11/10 Page 9 of 24CP0015aTOYOTA HILUX - CANOPY3 REPLACEFRONT SCUFF PLATEREPLACEHARDWARE2 REPLACEKICK driver s side kick panel andhardware as shown. Replace Front driver s side scuff plate.(ref. diagram19). masking tape to the sides of thebed liner, under each square slot in thecanopy side rails as shown. Apply tape to150mm below CANOPY side process for the other side of thevehicle. (ref. diagram21).Diagram: 21 - PROTECT BED LINERD iagram: 19 - REPLACE VEHICLE PARTSBED LINERAPPLYMASKING TAPETO BED LINERREPEATFOR ALLSIX (6) SLOTSSLOT IN CANOPYSIDE people are required for this the CANOPY onto the vehicle tubcarefully.