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Hilux (Double Cab) Hard tonneau cover Installation Instructions
Model year: 2015/04 Vehicle code: GUN1***-D***HW
Part number: PW3B1-0K008 Hard tonneau cover (grained finish) PW3B1-0K028 -** Hard tonneau cover (painted) PW3B1-0K102 Hard tonneau cover-side covers (grained finish) PW3B1-0K092-** Hard tonneau cover-side covers (painted)
Manual reference number: AIM 003 650-2
Ø 30mm
Ø 3mmØ 5mm
Ø 10mm
A:Sikkens® primer surfacer EP II
B:Sikkens® primer surfacer EP II Hardener
A:PRIMERB:ACTIVATOR
A:Standox® Etching Adhesion Primer 020 16167
B:Standox® Etching Adhesion Activator 020 16168
or
Teroson Multi-WAX Spray796107
Würth 0893 081-E/B
WAX
4 mm
Ø 10mmØ 12mmØ 13mmØ 17mm
Ø 12mmØ 13mmØ 17mm
3M 751
SikaflexRef.: 555
CLEANER / DEGREASER
10 mm
M8
MSDS
TDS
40°C
18°C
Manual reference number: AIM 003 650-2 2 of 28
Revision recordRev. No. Date Page Picture Update New Deleted steps
1 10.05.2016 All All X
2 20.06.2016 Various Various X
1x 1x
2x
2x
1x
4x6x
PW3B1-0K008 Hard tonneau cover (grained finish)PW3B1-0K028-** Hard tonneau cover (painted)
PW3B1-0K102 Hard tonneau cover-side covers (grained finish)PW3B1-0K092-** Hard tonneau cover-side covers (painted)
J AF
Q
M
1xL
X Y 4x Z 30x AA 26x AB 20x AC 4x6x AD4x 4xX
4xK
4xAE
8x N
2x R 4x S 2x T 2x U 4x V 4x W
2x O 2x P 1x AF 1x AG
M6
M8
M6 M6 M6
LH RH
2x
M8X20 M8 M8 M8 M8 M8 OD25 ID8.3
M8X35
Manual reference number: AIM 003 650-2 3 of 28
PROTECTION
x2
M8
AF
2
3
3
X
X
1 CLEANER / DEGREASER
Manual reference number: AIM 003 650-2 4 of 28
3
1
2
N
LAF
3
1
2x
10mm
2
0 mm
2
A A
1
Manual reference number: AIM 003 650-2 5 of 28
5
4
N
X
U
V
L
L
2x
Ø 3 mmØ 5 mm
3 10 mm 2
6x
Ø 3 mmØ 5 mm
5 10 mm 4
1
2x
1 2
6x
Manual reference number: AIM 003 650-2 6 of 28
7
6
L
WAX
1 4
6 7
3mm
30 min.
21°C
8
21°C
3
10 min.
MAX 15 min.1 6
2
3x 3x
2x
5
3mmCLEANER / DEGREASER
Manual reference number: AIM 003 650-2 7 of 28
8
3
1
2x
10mm
2
8 Nm
S
Manual reference number: AIM 003 650-2 8 of 28
9
N
X
U L
V
30 mm 30 mm
x81
2
4
1
2
4
3
SikaflexRef.: 555
SikaflexRef.: 555
Manual reference number: AIM 003 650-2 9 of 28
10
M M
M M
M
2x 2x
2x
8x
LH = RH
1
2
1
1
2
3
Manual reference number: AIM 003 650-2 10 of 28
12
11
K
AG
AA
Z
AB
PAF
V
V
U
U
W
W
0 mm 0 mm
SEC. D-D SEC. C-C
SEC. B-B SEC. A-A
X=X
B
B
A
A
XX
C
C
D
D
Manual reference number: AIM 003 650-2 11 of 28
13
K
K
K
K
1
0 mm
x6
2
1(5) mm
Manual reference number: AIM 003 650-2 12 of 28
14
6x
Ø 3 mmØ 5 mm
Ø 10 mm
2 10 mm 1
WAX
3 67
8 930 min.
21°C
10
21°C
5
10 min.
MAX 15 min.2 8
4 3mm
3mm
CLEANER / DEGREASER
3
3
1
2
Manual reference number: AIM 003 650-2 13 of 28
16
15
LH = RH
10 mm
1
SikaflexRef.: 555
Ø6mm
CLEANER / DEGREASER
2
2
3
4
Manual reference number: AIM 003 650-2 14 of 28
17
6x
12 mm
1
2
Manual reference number: AIM 003 650-2 15 of 28
18
X Z AA
AC
Bedliner Bedliner
Ø 30mm
ALUMINIUM BEDLINERPW3B1-0K002
PW3B1-0K002 PW3B1-0K010
UNDER RAIL BEDLINERPW3B1-0K010
Ø 30mm
45°45°
> 0mm
45°
13mm 17mm
1 23
1
1 22
For full Installation instructions
http://www.toyota-tech.eu
Manual reference number: AIM 003 650-2 16 of 28
19
S
32
1
SikaflexRef.: 555Ø6mm
4
5
30mm
30mm
CLEANER / DEGREASER
Manual reference number: AIM 003 650-2 17 of 28
20
O
SikaflexRef.: 555
Ø6mm
Manual reference number: AIM 003 650-2 18 of 28
22
21
J
4x
4x
18 Nm13mm
SEC.
1
2
13mm
S
Manual reference number: AIM 003 650-2 19 of 28
24
23
J
L
XAA
Z
AB
X≠X
SEC. B-BSEC. A-A
X X
X=X
SEC. B-BSEC. A-A
X X
X
LH/RH
X=X
A A BB
Manual reference number: AIM 003 650-2 20 of 28
25
K
J
D D
E
E
F
F
CC SEC. D-D SEC. C-C
X=X
(X) mm(X) mm
SEC. E-E SEC. F-F
X=X
(X) mm(X) mm
X=XX=X
ClickClick
Click Click
Manual reference number: AIM 003 650-2 21 of 28
27
26
K
4x
12 mm
SEC. A-A
A
A
A
A
6x
18 Nm12mm
8x
18 Nm12mm
2x
8 Nm10mm
3 2
1
12mm
12mmLH = RH
S
S
S
Manual reference number: AIM 003 650-2 22 of 28
29
28
Q
AD Z Y
R
4x
4 mm
1 4x
4 mm6 Nm
3
2
CL CL
S
2
4x
12 Nm12mm
3
2
ClickCL
1
ClickCL
1
ClickCL
1
S
Manual reference number: AIM 003 650-2 23 of 28
30
31
31
Manual reference number: AIM 003 650-2 24 of 28
OWNER’S MANUAL
CABLE ADJUSTMENT
4x
4 mm
4
5
1 2
3
CL CL
LH=RH LH=RH
LH RH
10mm
Model year: 2015/04 Vehicle code:
GUN1***-D***HW
Part number:
PW3B1-0K008 Hard tonneau cover (grained
PW3B1-0K028- ** Hard tonneau cover (painted)PW3B1-0K102 Hard tonneau cover-side covers (grained finish) PW3B1-0K092- ** Hard tonneau cover-side covers (painted)
KG
CAUTION
4x
4 mm6 Nm
6
S
Manual reference number: AIM 003 650-2 25 of 28
Manual reference number: AIM 003 650-2 26 of 28
CHECK SHEET
VIN n°
Model / Year Hilux (Double Cab)2015/04
Hard tonneau cover
P/N = OK
Owner’s
manual
=A =B
LH = RH
SEC.
1
3
2
Serial NumberCLICK
Click
1
118Nm
4x6Nm
4x12Nm
4x
2
3
2 3 ...S BLH RH
A BA
8Nm2x4
4
Manual reference number: AIM 003 650-2 27 of 28
1 2
3
3
Installation Date: Stamp:Technician Name & Signature:
. . / . . / . . . .
LH = RH
LH = RH
3x
= OK
= OK = OK
1
2
1 2
2xClick
1xClick
Serial NumberCLICK
Click
1
18Nm
2x18Nm
6x18Nm
8x
2
3
2 3 ...
S
BLH RH
A BA
Manual reference number: AIM 003 650-2 28 of 28