EGR ATC0021 User manual

ATC0021 (silver) ATC0002 (Black)
Page 1 of 12AT0021FIc 14.03.14
Place these instructions in vehicle’s glove box after installation is complete
Clean Tonneau Cover with a mild
detergent and water solution. Do not use abrasive cleaners or solvents.
Care Instructions:
WARNING!
When in the closed position, Aluminium Tonneau Cover must be latched and tailgate must be closed.Failure to do so could result in
unexpected opening of the Tonneau Cover from sudden wind gusts or driving conditions, which could cause damage to the vehicle
and/or your Aluminium Tonneau Cover.
Secure any items tall enough to strike the Tonneau Cover lock mechanism.
DO NOT close the Tailgate when theAluminium Tonneau is in the closed position, as damage may occur to the vehicle and/or your
Tonneau Cover.
Do not operate vehicle while cover is open.
MAINTENANCE:
- Avoid the use of chemicals to clean painted surfaces, wash regularly with car wash detergent, hose off and chamois dry.Aluminium
top sheet finish can be maintained with briteshine polish or similar. Un-maintained product i.e. surface finish degradations not covered
by warranty.
- The gas struts are self lubricating and should only be cleaned occasionally with a damp cloth. Premature seal failure will result if
solvents or lubricants are used to clean struts.
- Gas struts must be connected with the cylinder (wide) end to the Aluminium Tonneau Cover or Warranty is Void.
- The locking mechanisms and latches only require occasional lubrication with Graphite Powder.
- DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.
- All installation hardware and fasteners must be checked every so often for tightness.
TONNEAU COVER - IMPORTANT:
- Read instructions carefully before installation. It is strongly recommended that installation is conducted by a qualified mechanic.
- This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.
- 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 latch Tonneau Cover before operating vehicle.
- Do not carry open volatile chemicals with Tonneau Cover installed.
- If contact with volatile chemicals occurs clean Tonneau Cover with mild detergent and water solution.
- Recommend installation by 2 people.
• Fitting Instructions must be given to the end customer to understand correct removal and replacement process onto the vehicle.
Installation Time: Approx . 60 Minutes
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VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover

Page 2 of 12
Tonneau Cover Assembly x1 Hinge Bracket x2 Striker x2Striker Bracket x2
M10 Washer x8
M8 Washer x2
Gas Strut x2 Ball Stud x4
Gas Strut Bracket x2 M6 Button Head
Cap Screw x4
M6 Nut Plate x2M6 Washer x4 4.8x10 Rivets x16 Tailgate Lock Bracket x2
M10 Nut x8
M8 Lock Nut x4
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc
REQUIRED TOOLS | EQUIPMENT
13mm and 17mm Socket
½” Drive Ratchet + Extension Bar
8mm, 13mm and 17mm Spanner
Power Drill
5mm Drill Bit
8 mm Drill Bit
4mm Allen Key
Rivet Gun
Tape Measure
Centre Punch
Hammer
Pencil / Marker
Cleaning Materials
Masking Tape
Right Angle
Rust Inhibitor
Personal Protective Equipment:
Safety Glasses, Ear Plugs, Gloves
(Scissors, Silicone)* Optional
Foam Pad x1

Page 3 of 12
Required tools: Masking Tape, Marker Pen and
Tape Measure.
Step 1
Required tools: Marker pen, tape measure, right
angle.
1. Mark another line 86mm outboard from
this line, and a line 14mm from front
rail inner surface, crossing both lines
(use right angle and tape measure).
Repeat for both sides.
2. Align Hinge Bracket to marked lines and
check alignment. Repeat both sides
Step 2
Required tools: Power drill, 8mm drill bit, centre
punch, hammer.
1. Centre punch hole locations (4x)
3. Apply rust inhibitor to the drilled holes.
2. Drill through using 8.0mm drill bit and
remove drill burr from the holes.
Step 3
NOTE: If fitted, cabin guard must be removed.
NOTE: This instruction is for plain tub
installation only. If tub liner is fitted, the liner
will need to be trimmed to allow correct
installation of the tonneau cover brackets
and hinges. No spacers or additional media
allowed between hinges/brackets and the
vehicle tub.
1. Clean the top surface of the tub.
2. Apply masking tape on front rail top
surface and mark a centre line accurately.
Mark lines 507mm from the centre line
to both sides.
507mm
86mm
507mm
14mm
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc

Page 4 of 12
Required tools: 4mm Allen Key.
1.
Position hinge bracket and secure with
supplied M6 bolts, washers and nutplate.
Finger tighten only. Repeat both sides.
2. Align both Hinge Brackets equal from the
front rail inner surface and tighten the
bolts to 10Nm. Repeat both sides.
Step 4
Required tools: Tape Measure, Marker Pen and
Masking Tape.
1. Apply masking tap to the side rail inner
surface and measure 885.0mm from the
front rail inner surface, and mark location.
2. Mark another line 37.0mm from this line,
and a line 11.0mm from the side rail
bottom edge, crossing both lines.
3. Repeat for both sides.
Step 5
Required tools: Centre Punch, Marker Pen,
5mm Drill Bit and Power Drill.
1. Align Gas Strut Bracket with marked lines
to confirm hole locations.
2. Mark and centre punch hole locations.
3. Drill holes through using 5.0mm drill bit,
and remove any drill burr from holes.
4. Repeat for both sides.
Step 6
885 37mm
11mm
mm
5. Apply rust inhibitor to the drilled holes.
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc

Page 5 of 12
Required tools: Rivet gun, 13mm spanner and
13mm socket and driver.
1. Install the gas strut bracket with supplied
rivets.
2. Install the pivot end ball to the bracket and
tighten it to 20.0 Nm
Step 7
Required tools: 13mm spanner, 13mm socket
and driver
1. Install the ball stud with supplied nut and
washer in the middle hole of the Tonneau.
2. Repeat for other side.
3. Connect both gas struts by pressing it's
end into the ball studs.
Step 8
Required tools: -
1. Install the cover by letting the hinge
tongue to rest on front of the hinge
groove while holding the cover in a 60°
angle.
2. Move the cover toward the vehicle cabin
to slide the tongue to the groove, ensure
hinge parts fully engage.
DO NOT LOWER THE COVER YET.
NOTE: When lowering the cover,
ensure the front seal is not crushed
between the front rail and the cover.
NOTE: Note, the opening height of the
tonneau cover can be adjusted by fixing
the ball studs in either holes illustrated.
NOTE: Ensure the gas strut is installed
in the correct orientation as shown. The
wide end connects to the Tonneau cover.
Step 9
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc
Thin end
Mounts to
Vehicle Tub
Wide end
Mounts to
Tonneau Cover

NOTE: If the cover does not line up
correctly, move hinge parts mounted
to the front rail forward or backward,
one at the time.
Required tools: -
1.
While holding the cover up, insert the gas
strut ends the brackets, by firmly pushing
them in.
Step 10
Page 6 of 12
Required tools: -
1. Close the cover by pulling from the handle
and slowly close it while checking that the
cover is correctly lined up to the tub and
the latch mechanisms are not touching the
tub’s side rails.
2. Once confirmed the cover is lined up
correctly, leave it fully open.
Step 11
Required tools: 8mm Spanner.
1. While the cover is open and tailgate is
open. Press the latch rotor to closed
position, both sides.
2. Rotate the handle slowly to clock-wise,
ensure both latches disengage at the
same time. Adjustment may be required.
NOTE: Mechanism can be adjusted
by tightening or loosening the latch
rod M5 nuts from underneath the
cover.
.
Step 12
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc

Required tools: -
1. While the cover is open, check the front
seal’s lip is not trapped between the cover
and the front rails by bending it up.
Step 13
Page 7 of 12
Required tools: Masking Tape, Marker Pen,
and Tape Measure.
1. Apply masking tape to the rear section of
the side rails and side wall below.
Lower the tonneau cover. Mark the centre
of the tonneau cover latch on the masking
tape on the top surface of the side rail.
2. Using tape measure, marks line 1277.0 mm
from the front rail inner surface.
3.
4.
Mark another line 35.0 mm, towards the
tailgate.
Step 14
Required tools: Marker Pen
1.
Mark one more line 16.0 mm from the side
rail bottom edge, crossing two previously
marked lines.
Step 15
1277mm 35mm
16mm
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc

Required tools: Marker pen.
1. Take the striker bracket and line up the
top holes with marked location in the side
rail.
Mark up the bottom hole location, using
the bracket as template.
2.
Repeat for other side.
Ensure bracket top surface is horizontal
and that the line marked in step 14 lines
up with the centre of the bracket.
3.
4.
Step 16
Page 8 of 12
Required tools: Power drill, 5mm drill bit and drill
1. Remove the bracket, take centre punch
and centre punch the hole locations,
4x per side.
2. Using 5.0 mm drill bit, drill the holes, only
through the first layer of steel. Remove
any drill burr from the holes.
3. Repeat for other side.
Step 17
Required tools: Rivet gun.
1. Install the bracket using supplied rivets.
Step 18
.
bit stopper, centre punch, hammer.
NOTE: Use drill stopper to avoid
drilling too deep.
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc
4. Apply rust inhibitor to the drilled holes.

Required tools: -
Required tools: -
Required tools: 17mm spanner, 17mm socket
and driver.
1. Install the striker to the striker bracket
using supplied hardware.
2. The striker should line up with the top
surface of the side rails, fine adjustment
required.
Step 19
Page 9 of 12
1. Slowly close the cover and move the
striker sideways to line it up with the
latches. Ensure both sides are lined
correctly.
Tighten the striker nuts to 30.0Nm.
2.
3.
Adjust the striker height correct by first
closing the cover and measuring the gap
between the cover and side rails top
surface. The gap should be 9.0 mm at
the rear, adjust strikers accordingly.
Step 20
NOTE: Tailgate locking brackets are
included for added security, if you do
already have tailgate lock installed or
do not require this feature, please go
to step 26.
Step 21 (Optional)
NOTE: Do Not Close the tailgate.
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc

Page 10 of 12
Required tools: Marker Pen.
1.
2.
3.
Use the other bracket to create a gap
between the tailgate top surface and
tailgate lock bracket. as shown. Mark
the centre of the two holes.
Align tailgate lock bracket with marked
lines to confirm hole location.
Repeat for the other side.
Step 23 (Optional)
Required tools: Centre punch, hammer, drill, 5mm
drill bit, drill bit stopper.
1. Centre punch the hole locations (4x)
2. Drill holes using a 5.0 mm drill bit and drill
stopper.
3.
4.
Remove drill burr from the holes.
Step 24 (Optional)
Required tools: Masking tape, marker pen,
and tape measure.
1. Apply masking tape on both corner of the
tailgate top surface and first 30 mm of
inner surface.
2. Mark a centre line accurately. Mark lines
580.0mm from the centre line to both
sides.
3.
580mm
20mm
20mm
580mm
Mark another line 20.0 mm outboard from
this line.
Step 22 (Optional)
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc
Apply rust inhibitor to the drilled holes.

Required tools: -
Required tools: Rivet gun.
1. Install the tailgate lock brackets with
supplied rivets.
Step 25 (Optional)
NOTE: Ensure the keys do not get
locked inside the tub.
NOTE: Incorrect installation of gas strut will
void Tonneau Cover warranty.
Page 11 of 12
1. Ensure all the parts are correctly installed.
2. Open the tailgate.
3. Close the cover slowly and ensure locking
mechanism functions correctly.
Repeat step 3 ten times.
5.
4. Fully open the cover.
6. Close the tailgate.
7. Close the cover again slowly ensuring the
tailgate lock brackets are lined up correctly
(if installed) and the cover closes fully.
Step 26
14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc
Required tools: -
1. Ensure the gas strut is installed in the
correct orientation as shown. The wide
end connects to the Tonneau cover.
Step 27
Thin end
Mounts to
Vehicle Tub
Thin end
Wide end
Mounts to
Tonneau Cover
Wide end

Page 12 of 12 14.03.14
ATC0021 (silver) ATC0002 (Black)
VW AMRK Dual Cab (1st Gen) - Aluminium Tonneau Cover
AT0021FIc
Required tools: scissors.
1. Use supplied foam seal to improve weather
resistance of the tub when required. Silicone
may be applied to seal smaller gaps.
Step 28
NOTE: Common area of water ingress is
the seam between the side and front panels.