AUSSIE TONNEAU ATB01233 Install guide

TONNEAU COVER FITTING INSTRUCTION
Isuzu D-Max MY15-5 Dual Cab
With Headboard
July 2016 –August 2020
Part Number: ATB01233
1. TONNEAU COVER FITTING
NOTE: Read entire instructions prior to start.
1.1 BASIC TOOL REQUIRED
Drill, 4mm Drill Bit, Tape Measure, Rivet Gun, Marking Pencil / Pen, Clear Silicone / Silicone Gun
1.2 CONTENTS
1 x Tonneau Cover 2 x Bar Brackets 16 x Rope Buttons
1 x Tonneau Support Bar 22 x Rivets 2 x Dowel
1.3 TONNEAU COVER INSTALLATION PROCEDURE
NOTE: Remove swarf and apply the provided Rust Inhibitor to all drilled holes prior to riveting. Read
entire instructions prior to start.
1. With the pencil mark the inside edge on each side of the tub at 740mm from the inside front
face of tub towards the rear on each side. Centrally locate the bar bracket over this position
and align the top of the bar bracket 10mm down from the top edge of the tub and drill and
rivet bracket into place. See Figure 1. Repeat for other side of tub. Fit tonneau support bar to
bar brackets.
2. Attach the plastic front of the tonneau cover onto the headboard at the front of the vehicle.
3. Ensure tonneau is centred. To fit the rope buttons to the tub, start with the tailgate, vertically
line up each button to each bunji loop starting from the centre bunji loops. The height for the
buttons on the tailgate is 410mm UP from the bottom edge of the tailgate. Work from the
centre out, alternating from side to side. Attach each bunji to the button as it is fitted.
4. To fit the rope buttons to the sides, vertically line up each button to each bunji loop starting
from the rear bunji loop, alternating from side to side working towards the front. The height

for the side rope buttons are all measured down from the TOP INSIDE EDGE of the tub. For the
rear button measure 160mm, 165mm for the second button from the rear, and 170mm for the
next two buttons. For the button closest to the front of the tub measure 175mm down and
25mm back from the front edge of the tub. Attach each bunji to the button as it is fitted.
NOTE: All measurements are to be taken from the TOP INSIDE EDGE of the tub.
Figure 1
2. CARING FOR YOUR TONNEAU
Apply bee's wax or Dri-lube to 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 brush to clean tonneau.
Never drive without tonneau support bars in place as flapping can cause a delaminating effect on the
material.
"Tonneau is not designed to be used as a load restraint"
3. MULTI-FITT SUPPORT BAR
The Aussie Tonneau Multi - Fit Support Bar is designed to fit almost all Utes on the Market, from
Suburu Brumbys to Cab Chassis aluminium trays.
3.1 BASIC TOOL REQUIRED
Drill, 4mm drill bit
3.2 MULTI SUPPORT BAR CONTENTS
- 1 x hollow bar centrepiece - 2 x grub screws
- 2 x solid bar end piece
Place the bar bracket
with the beveled edge
facing up 740mm
740mm
10mm down
from top
edge of tub

3.3 FITTING MULTI SUPPORT BAR
1. Insert solid bar pieces into either end of hollow tube. Adjust bar so it fits between bar bracket
holders with the holes facing to the ground (so the grub screws don’t rub against the tonneau),
as shown above and then with a white pencil make a mark through the small holes of the
hollow bar onto the solid ends. This is where you will drill a hole to the depth of about 1-2mm
(do not go any further)
2. Join the pieces back together and screw grub screws through the hollow bar into the holes
that you drilled. Make sure you do not over tighten the grub screws. Refit the bar. You may
kink the bar in the middle to give it some extra height to assist with water runoff.