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.

25
25
34 34
10mm
916mm
TUB
TUB
TUB
20. One at a time, remove the backing papers from the anti-abrasive tape patches and apply to the tub as shown above
on the forward most past of the side rail. Repeat until all patches are applied. Smooth out the patches to remove any air
bubbles. Note: the small patches are applied at the front of the tub and large ones at the rear. Repeat for RHS.
See Dia #20.
21. Remove the front and rear brackets and foot cups from the sports bar. Retain all the hardware.
Note: Run M8 tap through sports bar mounting brackets. See Dia #21.
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870 TC0403c
Page 11 of 34
Accessory Part No. PZQ70-89870
ISSUE 4: 09/10/18
Diagram #20
AA
19. Align lock striker bracket (10) to the holes position “A” on the LHS. NOTE: Striker side marked “B” must attach to the
tub as shown. Place the support bracket (33) inside the tub and secure using M6 bolts, washers and nuts, (Torque 8Nm).
Repeat for RHS. See Dia #19.
Diagram #19
SIDE RAIL
SECTION VIEW
SECTION VIEWS
10
35
19
33
14
21
Diagram #21
B“B” side up
TORQUE 8Nm
FRONT
T50

22. Ensure the inside of the foot caps is clean. Apply a 6mm bead of non acetic silicon (not supplied) around the inside
surface of the foot cups. Remove tape liner from foam gasket and apply to base of foot cups as shown, Ensure LH and RH
gaskets match up with foot cup cut-out. Re-attach foot cups to the sports bar feet to ensure silicon seals foot cups. Ensure
silicon does not protrude above foot cups. See Dia #22.
24. Flip the sports bar over and place on a piece of cardboard to avoid damage. Fit the infill panel to the sports bar, secure
the sports bar foot brackets loosely using previously removed hardware. LHS shown, repeat for RHS. See Dia #24.
LHS SHOWN
FOOT CUP
FOOT CUP
SPORTS BAR
BOLTS
LHS SHOWN
DO NOT TIGHTEN FULLY
SILICON INSIDE
SILICON INSIDE
Page 12 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
23. Fit the sports' bar brackets into the infill panels as shown. NOTE: due to the shape of the front bracket, carefully
install the bracket on an angle to avoid damaging the paint. See Dia #23.
Diagram #23
Diagram #22
Diagram #24
26
27
INSERTAND SLIDE UPWARDS
T50

28
25. Secure the LHS infill panel against the sports bar feet, using the supplied shoulder bolts (28) and large M8 washers
(37). Do not tighten fully to allow infill panel alignment on the tub. Note: 2 washers are used per shoulder bolt. Repeat for
the RHS infill panel. See Dia #25.
26. NOTE: Two people are required for this step. Carefully position the sports bar assembly on the vehicle. Ensure that the
sports bar and infill panels are sitting firmly on the top of the tub bed rails and that the sports bar is centered on the vehicle,
torque all four sports bar vertical bolts to 52Nm.
Push down on sports bar to compress the foam seal on the foot cups and tighten all 12 attachment bolts to 35Nm in the
following order: 1. Front bracket forward facing bolts (LH & RH sides). 2. Front bracket side facing bolts (LH & RH sides).
3. Rear bracket side facing bolts (LH & RH sides). See Dia #26.
Page 13 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
ATTACH SPORTS BAR
Diagram #26
x4
37
x8
Diagram #:27
27. Ensure that the rear of the infill panel is sitting firmly on the bed rail of the tub (push down if necessary).
Mark and centre-punch the scrivet hole position. Repeat process for the other side of the vehicle. Carefully drill the
marked hole with 6mm drill and apply rust inhibitor. Repeat for RHS. See Dia #27.
Diagram #:25
12
Ø6mm
3
TORQUE TO 35Nm
T40

30. Check clearance of tonneau cover to vehicle rear corners. Ensure the tailgate is open and close tonneau cover.
Check clearances at both rear corners between tonneau cover and sheet metal. Gaps should be consistent. If tonneau
cover is touching sheet metal or gaps are not even, adjustment of the tonneau position may be required. Refer to the
Tonneau Cover Position Adjustment and Latch Position Adjustment section of this fitting instruction for more
information.
Note: If there is no adjustment required, torque all hinges and latches to 5Nm.
GAP
Page 14 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
Diagram #30
29. NOTE: Two people are required to carry out fitment of the Tonneau Cover. Carefully lift and fit the tonneau cover to
the vehicle. Ensure the hinges sit correctly in the header rail and that the tonneau flap/header rail seals are sitting
correctly (check that they are not pushed out of alignment or being pinched by the lid). Note: header rail seal should sit in
the slot cutout in the infill panel. Secure the tonneau hinges with hinge pins (8) hooked into header bar (4). See Dia #29.
8
8
1
4
Diagram #29
32
Diagram #:28
28. Secure the infill panels with a scrivet (32) on each side. See Dia #28.
A-DECK SECTION VIEW
FLAP SEAL
HEADER-RAIL
SEAL
FRONT

10
12
1
324
23
14
14
15
13
13
33. Assemble striker U-bolt (12), M6 small flat washers (14), M6 stainless spring washers (15) and M6 stainless
hex nuts (13) onto lock striker bracket (10). Adjust so the top of the striker U-bolt (12) is high enough for the latches
to reach second stage locking. Ensure that the tonneau lid seals contact the vehicle tub.
Tighten ensuring the distance to the top of the side rail is maintained, (Torque 8Nm).
Note: Refer to Striker Height Adjustment section of this fitting instruction for more information if necessary.
Note: Set striker height at 35mm for starting point. See Dia #33.
Diagram #:31
31. Attach the gas struts by clipping them into place as shown. See Dia #31
ENSURE THE GAS STRUTS ARE
ATTACHED AS PER THE PICTURES
ON THE DIRECTIONS ARROWS
MARKED ON THE STRUT BODY
GAS
STRUT
GAS
STRUT
GAS STRUT BRACKET
13mm
13mm
35mm
32. Adjust jacking bolts (23) until infill panels are level with the main surface of the Tonneau Cover. Once in the
correct position, lock the M8 Nut (24) into position against the bracket. Torque to 8Nm. See Dia #32.
infill panel
Page 15 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
Diagram #33
Diagram #32
TORQUE 8Nm
TORQUE 8Nm

20
44
20
34. Measure the length of exposed thread (Xmm) from bottom of the nut to the end of the thread. Measure length
(Xmm) on the rubber thread cap (20) and cut to length. Repeat for all four thread caps and fit to threads. See Dia #34.
(Xmm)
(Xmm)
Page 16 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
Diagram #35
Diagram #34
FOR FUTHER INFORMATION ON ADJUSTING THE TONNEAU COVER REFER TO PAGES 28-29
TRIM
EXCESS CLEAR
ABRASION TAPE
3TONNEAU NOT SHOWN FOR CLARITY
FOR THE ELECTRICAL INSTRUCTION TURN TO THE NEXT PAGE
SQUEEGEE OUT
EXCESS SOLUTION
BUBBLES
4
1
25% ISOPROPYL
ALCOHOL
75% WATER
APPLY
CLEAR
ABRASION TAPE
ALIGN
CLEAR ABRASION
TAPE WITH TOP EDGE
OF THE TAILGATE
2
35. Using a solution of 25% isopropyl alcohol and 75% water in a spray bottle (not -supplied) Thoroughly spray along
the top of the tailgate. Remove liner from clear abrasion tape. Working from one end with a 5mm overhang
to the side of the tailgate, place the clear abrasion tape (44) on the tailgate. Trim excess tape leaving a
5mm overhang at both ends of the tailgate. When in position use a squeegee to push out any excess water solution
and bubbles. Using a knife trim the tape to end of the tailgate. You may need to squeegee a few times.
When finished the tape is virtually invisible. To ensure a good finish please take care and do not rush this step.
See Dia #35.

Page 17 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
36. Important: Always refer to the vehicle’s Workshop Manual when removing vehicle components.
Note down all clock and radio settings. Disconnect the negative terminal of the battery (1) in the engine bay.
See Dia #36.
Diagram #36
37. At the front passenger side foot well area: remove front passenger scuff plate, remove the kick panel trim nut (2) and
remove the kick panel (3). See Dia #37.
Diagram #37
38. Unclip the glove box dampener (1). Remove LH retaining clip (2) by rotating anti-clockwise. Remove the glove box (3).
Remove the driver's lower dash garnish (4). See Dia #38.
Diagram #38
1
1
2
3
4
2
3
1

Page 18 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
39. Dislodge upper glove box trim (1). Unclip the upper glove box (2) and remove. See Dia #39.
Diagram #39
40. Locate and disconnect the 20-way hybrid junction connector (1) in the passenger side kick panel area. Identify the two
Lock/Unlock terminal wires as shown: See Dia #40.
Diagram #40
41. Using a precision screw driver, unclip the connector secondary lock (1). Carefully remove the two Lock/Unlock wires
from the rear of the connector using a precision screw driver. House the BLUE and GREEN lamp Relay Harness terminals
(2) into the rear of the connector cavities in the positions shown:
BLUE WIRE UPPER CAVITY (3). GREEN WIRE LOWER CAVITY (4).
Push the 20-way connector secondary lock (1) into place to retain terminals. See Dia #41.
Diagram #41
2
1
2
3
4
Blue
Green
1
Front view of 20-way connector
Pin 10
Pin 20
Connector Pin 10: Lock / Black Wire
Connector Pin 20: Unlock / White Wire
Front view of 20-way connector
1
1
Important: Ensure an audible ‘click’ is heard.

Page 19 of 34
Accessory Part No. PZQ70-89870
ISSUE 4: 09/10/18
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870 TC0403c
42. House the previously removed vehicle lock terminals into the supplied 1-way connectors (1) Push the secondary lock
into place to retain terminals. Important: Ensure an audible ‘click’ is heard. Connect the Relay Harness BLUE wire 1-way
connector (2) to the vehicle BLACK 1-way connector (3) Connect the Relay Harness GREEN wire 1-way connector to the
vehicle WHITE 1-way connector. Reconnect the 20-way hybrid junction connector to the vehicle. See Dia #42.
Diagram #42
43. Disconnect the 20-way junction connector (1). Scotch lock the Relay Harness terminal (2) to the 20-way junction
connector Pin 20 (3) RED wire/terminal. House the scotch lock terminal (2) with the supplied scotch lock housing (4).
Reconnect the 20-way junction connector (1). Disconnect the 20-way junction connector (1). See Dia #43.
Diagram #43
44. Route the two Relay Harness bases (1) up the vehicle harness (2) towards the LH glove box cavity area.
Secure the Relay Harness (1) to the vehicle harness (2) at every 150mm intervals with supplied Cable Ties. See Dia #44.
Diagram #44
1
1
1
4
42
2
3
3
Front view of 20-way connector
3
1
2
1
2
3
1

Page 20 of 34Accessory Part No. PZQ70-89870ISSUE 4: 09/10/18
Hard Tonneau Cover, A-Deck
Accessory Part No. PZQ70-89870
TC0403c
45. In the upper glove box cavity area, if vehicle is equipped with an ECU (1) in the location shown, remove vehicle nut
(2). Route Relay Harness ground ring terminal (3) to the vehicle grounding point (4) located in the upper LH glove box
cavity area on the I/P reinforcement bar. Fasten the ring terminal (3) using the existing nut (2) to the vehicle grounding
point (4). Note: If no ECU is present, use the supplied M6 Flange Nut to the grounding point (4). See Dia #45.
Diagram #45
46. In the engine bay area, secure the Power Harness male terminals (1) to the guide wire (2). Cut the LHS access point
(3). Note: If the LHS access point is occupied, use the RHS access point. Feed the guide wire (2) into the firewall grommet
(4). Ensure the guide wire breaks the internal grommet seal. Feed through until the Power Harness loop (5) reaches the
grommet and is facing down. Seal with silicon, then cable tie (6) around the access point. See Dia #46.
Diagram #46
47. In the glove box cavity area, retrieve the Power Harness (1) from the firewall grommet hole (2). House the five
terminals (3) on the end of the Power Harness to the supplied connector (4), in the positions shown in Table 1 and then
secure the secondary locks. Connect the housed Power Harness connector (4) to the Relay Harness 6-way
connector (5). See Dia #47.
Diagram #47
Important
Important
1
2
4
4
5
3
2
4
3
1
Important
Ensure the wire colours correspond between
the Sensor Harness and Relay Harness when
connected.
Front view of 6-way connector
1
3
2
4
5
6
Wiring Information
1
Table 1
BLACK
BLUE
GREEN
GREY
2
3
4
5
6RED
RED/BLACK
Important: Torque earth bolts between 6.9 & 9.8 Nm.
Important: Ensure the earth wire and Relay Harness
are free from sharp edges and pinch points.
1
6
1
2
3
5
Front of vehicle
6
1
2
1