Toyota PU100-3415S-01 User manual

TOYOTA TUNDRA 2016 - TONNEAU COVER
Preparation
Page 1 of 11 pages
Issue: C 04/18/2017 DIO
Part Number:
PU100-3415S-01, PK3B1-34H5H (Short)
PU100-3415R-01, PK3B1-34H6H (Reg.)
PU100-3415L-01, PK3B1-34H8H (Long)
Kit Contents
Item # Quantity Reqd. Description
1 1 Tonneau Cover
2 2 Side Rails (1 left, 1 right)
2 Drain Tubes
4 1 Hardware Bag
Hardware Bag Contents
Item # Quantity Reqd. Description
1 1 User Manual
2 1 Clamp Bracket
(10pc Short Bed, 12pc Regular
Bed, 16pc Long Bed)
3 1 T30 Torx, M6 x 1.0 x 30mm
Mounting Hardware
(10pc Short Bed, 12pc Regular
Bed, 16pc Long Bed)
4 1 Foam Seal Roll
5 1 Hex Key
Additional Items Required For Installation
Item # Quantity Reqd. Description
1 1 Bed Rails (if the vehicle is not
already equipped)
2
3
Conflicts
Bed Divider (PT767 34070) & Bed Liners that are not
compatible with Toyota accessory rails
GoPro® mount
General Applicability
All Tundra models with accessory bed rails
Recommended Sequence of Application
Item # Accessory
1 Bed Liner
2 Tonneau Cover
3 Accessory Rails
*Mandatory
Recommended Tools
Personal & Vehicle
Protection Notes
Safety Glasses
Wrist & Belt Buckle
Protection
Special Tools Notes
Installation Tools Notes
Torx Socket T-30 (Hardened), 3/8” Drive
Torque Wrench 200 N-m, 150 in-lbf, 3/8”
Drive
Ratchet 3/8” Drive
Ratchet Extension Short, 3/8” Drive
Drill
Drill Bit 3/4” dia.
Tape Measure
Scissors
Screwdriver Phillips #2
Plastic Mallet
Special Chemicals Notes
Vehicle Service Parts (may be required for reassembly)
Item # Quantity Reqd. Description
1
2
3
Legend
STOP: Damage to the vehicle may occur. Do not
proceed until process has been complied with.
OPERATOR SAFETY: Use caution to avoid risk of
injury.
CAUTION: A process that must be carefully observed
in order to reduce the risk of damage to the
accessory/vehicle and to ensure a quality installation.
TOOLS & EQUIPMENT: Used in Figures calls out the
specific tools and equipment recommended for this
process.
REVISION MARK: This mark highlights a change in
installation with respect to previous issue.
SAFETY TORQUE: This mark indicates that torque is
related to safety.

TOYOTA TUNDRA 2016 - TONNEAU COVER
Procedure
Page 2 of 11 pages
Issue: C 04/18/2017 DIO
Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this
accessory should follow approved guidelines to ensure a quality installation.
These guidelines can be found in the "Accessory Installation Practices" document.
This document covers such items as:-
Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.).
Safety (eye protection, rechecking torque procedure, etc.).
Vehicle Disassembly/Reassembly (panel removal, part storage, etc.).
Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.).
Please see your Toyota dealer for a copy of this document.
1. Prepare for the Installation.
(a) Before working on the vehicle, protect the
truck bed with covers.
(b) Remove the Tonneau Cover, Side Rails,
Drain Tubes and Hardware Bag from the
packaging. Identify the parts and check the
contents for any damage (Fig. 1-1).
(c) Remove the attached user manual from the
tonneau cover panel and place it in the glove
box.
(d) If the vehicle has factory bed rails, remove
them now (Fig. 1-2). Otherwise skip to Step
2.
(1) Use a T-30 Torx driver to remove the bed
rail mounting bolts.
(2) Keep these bolts in a safe place, as they
will be reused to mount the rails to the
tonneau clamp brackets.
(3) Pull the rail away from the bed sides to
remove it.
Fig. 1-2
T-30 Torx socket, ratchet & extension
Fig. 1-1

TOYOTA TUNDRA 2016 - TONNEAU COVER
Procedure
Page 3 of 11 pages
Issue: C 04/18/2017 DIO
(4) From the back side of the accessory rail,
use a plastic mallet to lightly tap the
locator peg towards the larger opening in
the “keyhole” in the rail (Fig. 1-3).
Remove and discard the peg.
NOTE: Remove two locater pegs per rail.
2. Install the Tonneau Cover Side Rails onto the
Truck Bed.
(a) Slide the clamps into the side rail grooves
(Fig. 2-1).
(1) Spread the clamps evenly along the
length of the rails.
(2) The exact location will be determined
when installing the rails onto the truck
bed.
(b) Place the tonneau side rail on the truck bed
(Fig. 2-2).
NOTE: Place the side rails on the truck bed so
that the endcap containing the drain is toward the
front of the bed.
(c) Position the tonneau side rails on the truck
bed 1” (25.4mm) back from the bed edge
(Fig. 2-3).
Fig. 1-3
Plastic mallet
Fig. 2-1
Fig. 2-2
Fig. 2-3
Tape measure
1 inch

TOYOTA TUNDRA 2016 - TONNEAU COVER
Procedure
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Issue: C 04/18/2017 DIO
(d) Align the slots in the clamp brackets with the
threaded holes in truck bed sides and install
the supplied mounting bolts (Fig. 2-4). Do
not fully tighten them at this time.
NOTE: To ensure proper alignment of the driver
and passenger side pins, make sure that both side
rails are placed exactly the same (Fig. 2-5).
(e) Tighten and torque the mounting bolts to 7.5
N-m (66.5 in-lbf), being sure to hold the rail
in place and PUSH the side rail DOWN
against the bed caps as the clamp is tightened
(Fig. 2-6).
Torque: 7.5 N-m (66.5 in-lbf)
NOTE: The top of the rail must contact the truck
bed side wall to ensure a good seal (Fig. 2-7).
CAUTION: If the vehicle is equipped with a
Toyota bed liner, ensure that the liner is not
sandwiched between the clamps and the truck
bed.
Fig. 2-4
T-30 Torx socket, ratchet & extension
Fig. 2-6
T-30 Torx socket & torque wrench
Fig. 2-7
Fig. 2-5
Tape measure
1 inch

TOYOTA TUNDRA 2016 - TONNEAU COVER
Procedure
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Issue: C 04/18/2017 DIO
(f) Align the slide-nut at the front of the side rail
so that the set screw aligns with the hole in
the rail (Fig. 2-8).
(g) Slowly tighten the set screw with the
provided hex key against the clamp bracket
until the side rail is level (Fig. 2-9).
NOTE: Do not overtighten the set screw such
that the side rail is no longer level.
(h) Install the drain tubes (2) onto the drain caps
(Fig. 2-10).
NOTE: Make sure the tube covers all the three
lines around the drain cap.
NOTE: If the vehicle is NOT equipped with a
Toyota bed liner or is equipped with a spray-on
bed liner, continue to Step 2(i). If the vehicle is
equipped with a Toyota bed liner, skip to Step
2(m).
(i) Remove the outermost drain plugs.
(j) Drill a 3/4" hole in each plug.
NOTE: Create the drain hole towards the bottom
of the plug/vehicle for better routing.
Fig. 2-8
Hex key
Fig. 2-9
Hex key
Fig. 2-10

TOYOTA TUNDRA 2016 - TONNEAU COVER
Procedure
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Issue: C 04/18/2017 DIO
(k) Reinstall the plugs and route the drain tubes
through the drilled holes (Fig. 2-11).
(l) Skip to Step 3.
(m)If the vehicle has a Toyota bed liner, route
the drain tube through the provided hole (Fig.
2-12).
3. Reinstall the Factory Bed Rails onto the
Clamp Brackets (if equipped).
(a) Use the factory bed rail hardware to install
the bed rails onto the bottom holes of the
clamp brackets (Fig. 3-1).
(b) Tighten and torque the mounting bolts to
7.5N-m (66.5 in-lbf), being sure to keep the
side rails fully seated on the bed rails.
Torque: 7.5 N-m (66.5 in-lbf)
Fig. 2-11
Fig. 2-12
Fig. 3-1
T-30 Torx socket, torque wrench & extension

TOYOTA TUNDRA 2016 - TONNEAU COVER
Procedure
Page 7 of 11 pages
Issue: C 04/18/2017 DIO
4. Install the Foam Seal.
(a) Clean the top surface before applying the
seal.
(b) Place the included foam seal on the front lip
of the truck bed (adhesive side down) below
the cab rear window from the driver side bed
rail cap to the passenger side bed rail cap
(Fig. 4-1). Remove the plastic backing and
affix the seal to the bed.
(c) Use scissors to cut the foam seal at an angle
to minimize the gap with the side rail cap
(Fig. 4-2).
5. Install the Tonneau Cover into the Side Rails.
(a) Unlock the latches and then lift the folded
tonneau onto the side rails. (Fig. 5-1, driver
side shown).
NOTE: Visually make sure the edge of the cover
is centered between the outer and inner edges of
the accessory rail on each side.
(b) Stand the bundled panel system on the side
rails so that the retaining hooks line up with
the two pins inside the side rail (Fig. 5-2).
Fig. 4-2
Scissors
Fig. 5-1
Fig. 5-2
Fig. 4-1

TOYOTA TUNDRA 2016 - TONNEAU COVER
Procedure
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Issue: C 04/18/2017 DIO
(c) Place the center panel down first, being sure
to engage the mounting hooks in-between the
two rearmost retaining pins on both side rails
(Fig. 5-3).
(d) Attach the safety cables to the underbody
rails on both the driver and passenger sides
(Fig. 5-4).
NOTE: Ensure the safety cables are securely
attached by checking that the spring clip is under
the pin flange (Fig. 5-5). Repeat for the other
side.
(e) Unclip the retention straps from the cab panel
and carefully fold the panel forward (Fig. 5-
6).
Fig. 5-3
Fig. 5-4
Fig. 5-5
Fig. 5-6

TOYOTA TUNDRA 2016 - TONNEAU COVER
Procedure
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Issue: C 04/18/2017 DIO
(f) Visually confirm that the front latches are
aligned with the pins in the side rails (Fig. 5-
7) and gently lower the cover to ensure that
nothing contacts and causes damage. Slight
misalignment can be fixed by making sure
the mounting hooks in the center panel are
fully seated against the retaining pins in the
side rails.
(g) Press down on the cab panel to lock it in
place. Lift up on the panel to make sure the
panel latched properly (Fig. 5-8 to Fig. 5-10).
NOTE: If the front latches do not latch properly,
open the front panel, check the alignments and
try again (Fig. 5-11).
Fig. 5-7
Fig. 5-8
Fig. 5-9
Fig. 5-10
Fig. 5-11

TOYOTA TUNDRA 2016 - TONNEAU COVER
Procedure
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(h) With the tailgate open, unfold the tail panel
into the closed position and push it down
onto the truck bed (Fig. 5-12 & Fig. 5-13).
6. Check the Tonneau Cover for Fit.
(a) Check to see that each tail panel latch makes
proper contact with the side rails (Fig. 6-1).
(b) If the tail panel does not contact the side rails
properly (Fig. 6-2), hand loosen the latch
screws, slide the latch toward the side rail
and retighten the screws by hand (Fig. 6-3).
Fig. 5-12
Fig. 5-13
Fig. 6-1
Fig. 6-2
Fig. 6-3
Phillips screwdriver

TOYOTA TUNDRA 2016 - TONNEAU COVER
Checklist - these points MUST be checked to ensure a quality installation.
Check: Look For:
Page 11 of 11 pages
Issue: C 04/18/2017 DIO
Accessory Function Checks
Rails fully seated on bed sides
Rails installed flat (level)
Latching of both front latches
Tonneau latches
Correct alignment of white rear latch
wedges
Rear latch wedges
Safety cables attached to tonneau panel
If the vehicle is equipped with a Toyota bed
liner, ensure that the liner is not sandwiched
between the clamps and the truck bed
Vehicle Function Checks
Tailgate latches
Gap or folded lip seal to bed surfaces
Rail position flat (level), not pitched
upward or downward
Proper full double latching
Tonneau latches are fully engaged and
aligned to side rail pins
Clamp too low pulling side rail down
Full engagement of rear latch wedges
Both safety cables are connected
Both safety cables are securely attached
Liner is not sandwiched between the
clamps and the truck bed
Tailgate latches properly
Vehicle Appearance Check
After accessory installation and removal of
protective cover(s), perform a visual
inspection.
Ensure no damage (including scuffs and
scratches) was caused during the
installation process.
(For PPO installations, refer to TMS
Accessory Quality Shipping Standard.)