Toyota HILUX 'A' DECK User manual

Page 1 of 34
Place these instructions in vehicle’s glove box after installation is complete
Accessory Part No. PZQ70-89870 Installation Time: Approx. 4h 15min
Clean Tonneau Cover
with a mild detergent and
water solution.
Do not use abrasive
cleaners or solvents.
Care Instructions:
IMPORTANT!
Please check content of kit using this list and subsequent sketches. Advise discrepancies to TMCA at once.
Do not stand/sit or rest heavy objects on Tonneau Cover.
Do not carry open volatile chemicals with Tonneau Cover installed.
Humans or animals are not to be under the closed Tonneau Cover at any time.
Securely lock Tonneau Cover before operating vehicle.
Tonneau Cover is not dust or water tight.
If contact with volatile chemicals occurs clean Tonneau Cover with mild detergent and water solution.
PARTS, SERVICE & ACCESSORIES
MAINTENANCE
If lubrication of the locks or hinges 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 instructions before installation of accessory.
Always install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or
the accessory.
Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local
recycling regulations.
It is always recommended that this accessory is fitted by a qualified Toyota Technician.
Safely store and protect any removed vehicle components.
Ensure all bare metal surfaces are protected using Automotive Bare Metal Primer and touch-up paint.
Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.
General Notes

Rust
Inhibitor
Page 2 of 34
PARTS CHECK SHEET
Tonneau Cover
Qty - 1
PARTS IN MAIN CARTON
Header Rail
(HBAR0028)
Qty - 1
Fitting Kit
Qty - 1
Lock Key
(Attached to
Tonneau)
Qty - 2
Hinge Pin
(CLIP3243)
Qty - 2
Gas Strut
(STRT0005-2)
Qty - 2
Striker
Bracket
(CLIP2499PC)
Qty - 2
Striker U-Bolt
(LOCK0006)
Qty - 2
Jacking
Bracket
(CLIP2049-1)
Qty - 2
Ball stud
Bracket
(CLIP3151PC)
Qty - 2
Rust Inhibitor
(MISC2776)
Qty - 1
Sports bar
Front leg
Gasket
(TAPE0676)
Qty - 1 Pair
Sports bar
Rear leg
Gasket
(TAPE0676)
Qty - 1 Pair
Pop Rivet
(FAST0505)
Qty - 7
Alcohol Wipe
(MISC0052)
Qty - 2
PARTS IN FITTING KIT
AUTOMOTIVE
SURFACE CLEANER
IMPREGNATED WITH 70% ISOPROPYLALCOHOL
For use in cleaning painted metal,
glass and other vehicle surfaces.
For external use only.
Dispose of properly after use.
M6 Small S/S
Flat Washer
(WASH0153)
Qty - 16
M8 Flat Washer
(WASH00171)
Qty - 4
M8 Flat Washer
Large
(WASH0230)
Qty - 16
M6 Flat Washer
Large
(WASH0169)
Qty - 8
M6 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
12 3 45 6 7
13
8109 11 12 14 15
20
16 17 18 22 23
24 26
27
29 30 31
32 33 34 35 36 38 3937
40 41 42 43 44
Fitting
Instructions
Fitting
Instruction
(FIT-TC0403c)
Qty - 1
45
25 28
19 21
LHS Infill Panel
Qty - 1 RHS Infill Panel
Qty - 1
Header Rail
Seal
(MISC2229-9)
Qty - 1
Anti-abrasive
tape-Large
(TAPE0675)
Qty - 2
Anti-abrasive
tape-Small
(TAPE0258-6)
Qty - 2
TC0403c
Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
M8 Nylock
(NUTS0242)
Qty - 2
Primer Stick
(MISC1365)
Qty - 2
Scrivet
(FAST0086)
Qty - 2
Support
Bracket
(CLIP3142PC)
Qty - 4
B
M5 Nylock Nut
(NUTS0171)
Qty - 2
M5x16 Hex
Head Bolt
(SCRW0450)
Qty - 2
M5 Flat Washer
(WASH0190)
Qty - 4
Pin Switch Plate
(CLIP3141PC)
Qty - 1
Harness Bracket
(CLIP3304PC)
Qty - 1
Wiring Loom
(LOOM0082)
Qty - 1
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
Anti-abrasive
Tape (TAPE0698)
25mm x 1.55m
Qty - 1

PARTS IN LOOM KIT
Tools Required:
• Pen / Marker
• Centre Punch
• Drill & drill bits; Ø3mm, Ø5.5mm, Ø6mm,
Ø7mm & Ø9mm
• Phillips Screwdriver
• Torque Wrench
• Trim removal Tools
• Step Drill Ø25mm, Ø35mm
• M8 Tap
• T40 & T50 Torx Bit
• Caulking Gun
• Silicon - Non Acetic
• Die Grinder & multi tool
• Masking Tape
• Scissors & Knife
• Ruler
• Wire Cutters
• Drill Stop
• 10mm,12mm,13mm & 14mm
Spanner & Socket
• Rivet Gun
• Tape Measure
• Soapy Water Solution
• Allen Key Set (Metric)
• 35mm Hole Saw
• Ratchet
• Jeweller’s Flat Head Screwdriver
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
Page 3 of 34
TC0403c
Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Relay Harness x1
(locking variant only)
AB 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
GH
J
Mini Blade Fuse - x17.5A
I
Cleaning Pad x2
Adhesive Cable Tie
Mounts x4
K
Cable Tie -
Lamp only variant x25
Locking variant x35
200mm
Cable Tie - 600mm x3
L
Ø8mm P-Clip x2
MN
M6 Flange Nut x1
(locking variant only)
O
Ø6mm P-Clip x1
P
7x12 Cable Tie Clips x2
CLEANING
PAD

TC0403c
Page 4 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Toyota Hilux HTC
Installation Steps Flow Chart
START
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

Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
Page 5 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Diagram #3
COMPLETE STEP 3 TO 5 ONLY IF VEHICLE IS FITTED WITHA UTELINER
1. NOTE: Two people are required to complete installation. Prior 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. Thoroughly clean installation areas. See Dia #2.
Diagram #2
T40

RUBBER EXTRUSION
TRIM LINE
Diagram #4
4. Remove the rubber extrusion fitted to the top front edge of the ute liner. Draw a straight line along the front edge of
the ute liner, using the steps on each side as a marking point as shown (approximately 30-40mm to be cut down).
The rubber extrusion should be reused. See Dia #4.
Diagram #5
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
Page 6 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
DRILL Ø35mm 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 the drill (3) using a drill stop (4) to a depth of 10mm. Drill a pilot hole through the template crosshair
centre (5). Remove and discard the template (1). Using a stepped drill bit, drill out the previously drilled pilot hole to
Ø30mm. See Dia #6.
Diagram #6
10mm
4
3
12
5

Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
Page 7 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
9.Apply masking tape to the inside edge of the tub rail as shown. Measuring from the rear edge of the front bar, mark and
centre punch the indicated positions on the inside of the rail as shown. Repeat for the other side of the tub.
See Dia #9.
FRONT
TUB
PANEL
FRONT
MASKING TAPE
1368mm
1298mm 910mm
824mm
789mm
28mm
28mm
SIDE VIEW
2 3 4
CB B
AA
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 file (1) de-bur the hole (2) and remove any rough or sharp edges. Apply rust inhibitive compound around the
edges of the hole. See Dia #7.
Diagram #7
Diagram #8
Diagram #9
2
1
2

FRONT
MASKING TAPE
SIDE VIEW
CB B
AA
10mm
10. Set the drill depth to 10mm. Drill Ø3mm pilot holes first. Drill Ø7mm holes in positions A and B and Ø9mm in
position C. Repeat for the other side of the tub. Apply rust inhibitor to all drilled holes. See Dia #10.
Ø7mm
Ø3mm
12
Ø7mm Ø9mm
3 4
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
Page 8 of 34Accessory Part No. PZQ70-89870ISSUE 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 and clean fingers to manipulate and clean up the silicone bead
after applying. See Dia #12.
Diagram #12

15. Use the primer supplied to prime top of the header rail, where the header rail seal will sit. Remove the tape liner from
the bulb seal (4) and start applying the seal 100mm from one end of the header rail. Note the seal orientation shown in the
cross section. A pply firm vertical pressure to the bulb seal along its length to ensure good and even adhesion. Rubber
seal must be positioned correctly as shown. Follow the diagram above. See Dia #15.
5
54
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
TC0403c
Page 9 of 34Accessory Part No. PZQ70-89870 ISSUE 4: 09/10/18
Diagram #13
14. Reinstall the uteliner. See Dia #14.
Diagram #14
Diagram #15
100mm
LHS RHS
100mm

38
39
18. Align gas strut bracket (18) to hole position “B” on the LHS. Place the support bracket (33) inside the tub and secure
using M6 bolts, washers and nuts, (Torque 8Nm). Repeat for RHS. See Dia #18.
10mm
13mm
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
Page 10 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Diagram #17
Diagram #18
CC
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.
BB
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) to the top of the Header Bar and the Harness Bracket to the bottom using
two M5 bolts (39), washers (40) and Nylock nuts (38). Torque to 5Nm. See Dia #16.