CANOPY INSTALLATION INSTRUCTIONS NISSAN NAVARA D40 Double Cab - RX / ST / ST-X (with & without Nissan Genuine Bed Liner)

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1 INSTALLATION INSTRUCTIONS NISSAN NAVARA D40 Double Cab - RX / ST / ST-X (with & without Nissan Genuine Bed Liner) (For Australia: 005 Production Onwards for ST & ST-X) (January 009 Production Onwards for RX) Installation Time: Hour (Approximately) Care Instructions: Clean Canopy with a mild detergent and water solution. Do not use abrasive cleaners or solvents. Place these instructions in vehicle s glove box after installation is complete PLEASE REFER TO PAGE, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES. IF FITTING THE TO A 006 Production Onwards ST-X MODEL, THEN ADDITIONAL SUPPLEMENTARY KIT PART No:- D40STX-CNPY-HARN WITH FITTING INSTRUCTIONS (CP000) WILL BE REQUIRED. IMPORTANT! Read instructions carefully before installation. It is strongly recommended that installation is conducted by an authorized dealer. This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention. Recommend installation by people. This Canopy is designed to suit the Double Cab (4x & 4x4) RX, ST & ST-X Navara D40. Sports Bars MUST be removed & returned to Customer with all hardware components if required. Cabin Guards MUST be removed & discarded. This canopy is only designed to work with unboltable Cabin Guards on on RX models from January 009 Release. This Fitting Instruction where a Bed Liner is referred to, is based on - Nissan Genuine Under Rail Bed Liner Accessory only. RECOMMENDED TOOL LIST - (Not Supplied in Kit) Loctite 77 thread locking liquid (IMPORTANT) Phillips Head Screwdriver Large Flat Blade Screwdriver Medium Adjustable Spanner Side Cutters Sockets 0, & 3mm, Extension Bar and Driver Spanners 0, & 3mm Silicon Dispensing Gun Non Acetic Silicon (Neutral Cure) Spray Bottle (5% isopropyl Alcohol & 75% Water) Spray Bottle Water Torque Wrench - 0-0Nm Non Permanent Marker Masking Tape Cleaning Cloths / Rags Steel Rule and Tape Measure Scissors (Sharp) Knife (Sharp) Squeegee Metal Primer Light Gauge Plastic Coated Draw Wire Small Round File or Deburring Tool Ø5mm Drill Bit Rivet Gun for Stainless Steel Rivets Page of

2 IMPREGNATED WITH 70% ISOPROPYL ALCOHOL NISSAN NAVARA D40 - PARTS CHECK SHEET PARTS IN MAIN CARTON NISSAN NAVARA D40 Canopy Qty - Front Tub Stop Extrusion (ALUM0038-0) Qty - Front Tub Spacer Extrusion (ALUM0038-9) Qty - Lock Keys (Attached to Canopy Internal Rear Door Handle) Qty - Fitting Kit (KIT03043) Qty - PARTS IN FITTING KIT (KIT03043) Kit - Rail Clamps (CNPY0007) Qty - 6 Clear Abrasion Tape Roll 48mm Wide (TAPE06-) Qty - Tape EPDM mx0mmx6mm (TAPE0386) Qty - Screw M6x30 Hex Head SS304 (SCRW084) Qty - 4 M6 Flat Washer OD. 9mm (WASH069) Qty - 8 M6 Nyloc Nut SS304 (NUTS006) Qty - 4 Tape 406 GHBWH x700mmx.4 Thick Roll (TAPE065) Qty - Bulb Seal 70mm Cut Length (MISC600-) Qty - Rivet SS304 ST-ST 6-6 (FAST0505) Qty - 8 Clear Tape Pad 50x3mm Abrasion Resistant (TAPE00) Qty - 6 LH Tub Re-Inforcement Bracket (CNPY007PC-LH) Qty - 6 RH Tub Re-Inforcement Bracket (CNPY007PC-RH) Qty x35mm Label Sticker (LABL44) Qty - M8x5 Hex Head Bolt (SCRW0696) Qty - 0 M8 Flat Washer (WASH07) Qty - M8 Spring Washer (WASH05) Qty - 0 AUTOMOTIVE SURFACE CLEANER For use in cleaning painted metal, glass and other vehicle surfaces. For external use only. Dispose of properly after use. Rust Inhibitor Fitting Instruction M8 Hex Nut SS304 (NUTS07) Qty - Alcohol Wipe (MISC005) Qty - 4 Rust Inhibitor Satchel (MISC776) Qty - Primer Stick (MISC365) Qty - 5 Vehicle Wiring Patch Harness Kit (LOOM007) Qty - Fitting Instruction (FIT-) Qty - PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM007) Vehicle Wiring Patch Harness (LOOM007) Qty - Cable Ties (3) Long (7) Short Qty - 30 Adhesive Tie Pad Qty - 0 Amp Blade Fuse Qty - Page of

3 IF A SPORTS BAR IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP. IF A CABIN GUARD IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP. IF THE VEHICLE HAS NO CABIN GUARD OR SPORTS BAR PLEASE PROCEED TO STEP 4. 5mm. Remove the four (4) bolts holding the sports bar feet to the tub as shown. Carefully remove the sports bar from the vehicle and return to the customer with all hardware components. (ref. diagram). REMOVE HARDWARE Diagram: - REMOVE SPORTS BAR & HARDWARE mm REMOVE & RETAIN HARDWARE. Remove and retain the twelve () hardware items securing the cabin guard to the front rail as shown. (ref. diagram). Diagram: - REMOVE HARDWARE SECURING CABIN GUARD REMOVE CABIN GUARD 3. Carefully remove the cabin guard taking care to avoid scratching the paintwork. (ref. diagram5). OPTIONAL: If customer requests paint all areas left exposed as primed sheetmetal. Painting is preferred to prevent rust. (ref. diagram3). Diagram: 3 - REMOVE CABIN GUARD Page 3 of

4 4. At the rear left hand side of the vehicle locate the existing harness connectors and disconnect them. For RX, ST & pre 006 ST-X vehicle s connect the tail lamp connectors to the vehicle harness (LOOM007) connectors as shown. For 006 Production Onwards ST-X vehicle s, you will need to fit D40STX-CNPY-HARN using Fitting Instructions CP000 as detailed. Run the vehicle harness across the back of the vehicle to the right hand chassis rail, then follow the chassis rail to the front right hand wheel arch. Ensure the harness is positioned away from the exhaust system. Ensure the canopy connector is positioned on the chassis rail between the tub and the cabin as shown. Secure the vehicle harness with cable ties spaced 300mm - 400mm apart. Position cable ties away from fuel lines, brake cables,moving parts and flexible mounts to body. Trim excess cable tie length with side cutters. Ensure harness is run in a direct route from the rear of the vehicle to the front. (ref. diagram4). FRONT OF VEHICLE FUSE TERMINAL CONNECTION RIGHT HAND SIDE OF VEHICLE 4 RUN VEHICLE HARNESS ALONG CHASSIS RAIL FOR 006 PRODUCTION ONWARDS ST-X VEHICLE S REFER TO FITTING INSTRUCTION CP000 KIT NUMBER - D40STX-CNPY-HARN FOR RX, ST & PRE 006 ST-X VEHICLE S SEE BELOW 6 APPLY CABLE TIES EVERY MM 5 POSITION CONNECTOR UNDER THE GAP BETWEEN THE CABIN & TUB DISCONNECT EXISTING VEHICLE HARNESS CONNECTORS EXISTING VEHICLE HARNESS CONNECTORS VEHICLE HARNESS (LOOM007) 3 RUN VEHICLE HARNESS ACROSS THE REAR OF THE VEHICLE CONNECT EXISTING HARNESS CONNECTORS TO THE VEHICLE HARNESS CONNECTORS REAR LEFT HAND SIDE OF VEHICLE Diagram: 4 - CONNECT & RUN VEHICLE HARNESS UNDER THE VEHICLE Page 4 of

5 FEED DRAW WIRE OPEN BONNET WHEEL ARCH RH FRONT 3 ATTACH VEHICLE HARNESS 5. Open and secure the bonnet. Feed a draw wire down through the engine bay in the rear right hand corner where the inner right hand front quarter panel meets the firewall as shown. From under the left hand front wheel arch, attach the end of the vehicle harness to the draw wire. Using two () people, one person feeding the vehicle harness and the second person to pull the draw wire until the harness is at the top of the engine bay. Remove the draw wire. (ref. diagram5). FRONT OF VEHICLE CHASSIS RAIL Diagram: 5 - USING A DRAW WIRE PULL HARNESS INTO ENGINE BAY REMOVE REMOVE FUSE BOX CABLE CLAMP COVER 6. Remove the cover on fuse box carefully so you do not break the clipping tags. Remove the cable clamp securing the harnesses in the fuse box carefully so you do not break the clipping tags. (ref. diagram6). FRONT OF VEHICLE Diagram: 6 - REMOVE FUSE BOX COVER & CABLE CLAMP REMOVE HORN FUSE RX & ST VEHICLE S ONLY 7. Remove the horn fuse as shown (for RX and ST vehicles only). The horn fuse is in a different location on ST-X vehicles and does not need to be removed. (ref. diagram7). FRONT OF VEHICLE Diagram: 7 - REMOVE HORN FUSE FOR RX & ST VEHICLES ONLY Page 5 of

6 RELEASE ALL 3 CLIPS HOLDING THE FUSE HOLDER REMOVE FUSE HOLDER 8. Release the 3 clips holding the fuse holder as shown. Remove the fuse holder from the fuse box. (ref. diagram8). Diagram: 8 - RELEASE & REMOVE THE FUSE HOLDER CONTINUED OVER THE PAGE Page 6 of

7 9. Route canopy harness with existing harnesses as shown. Connect the canopy harness terminal to a spare fuse hole as shown. Fit the 0 amp fuse from the wiring harness hardware kit, to the spare fuse hole that lines up with canopy harness terminal as shown. (ref. diagram9). RX VEHICLE ONLY CONNECT TERMINAL TO SPARE FUSE HOLE ROUTE HARNESS 3 FIT 0 AMP FUSE HARNESS ST VEHICLE ONLY CONNECT TERMINAL TO SPARE FUSE HOLE ROUTE HARNESS 3 FIT 0 AMP FUSE HARNESS ST-X VEHICLE ONLY CONNECT TERMINAL TO SPARE FUSE HOLE ROUTE HARNESS 3 FIT 0 AMP FUSE HARNESS Diagram: 9 - FIT HARNESS & FUSE TO FUSE HOLDER Page 7 of

8 REPLACE FUSE HOLDER, ENGAGE ALL 3 CLIPS REPLACE HORN FUSE RX & ST VEHICLE S ONLY 0. Replace the fuse holder ensuring the (3) clips, clip back into position. Gently pull fuse holder to ensure it is clipped in correctly and can not be removed. For RX and ST vehicles replace previously removed horn fuse. (ref. diagram). HARNESS Diagram: 0 - REPLACE THE FUSE HOLDER & HORN FUSE REPLACE CABLE CLAMP REPLACE FUSE BOX COVER. Replace the cable clamp to secure the harnesses in the fuse box and ensure the clipping tags are engaged. Replace the cover on fuse box and ensure the clipping tags are engaged. (ref. diagram). HARNESS HARNESS Diagram: - REPLACE FUSE BOX COVER & CABLE CLAMP CLOSE BONNET NEATLY POSITION HARNESS & SECURE WITH CABLE TIES. Use cable ties to neatly position and secure vehicle harness. Close the bonnet. (ref. diagram). HARNESS Diagram: - NEATLY SECURE HARNESS & CLOSE BONNET Page 8 of

9 POSITION CARDBOARD TUB PROTECTION MAT 3. Thoroughly clean and dry installation areas (tub, rear of cabin and glass) as shown. Using cardboard cut from the canopy carton, cut and place a piece inside the tub on the floor as a protection mat while installing the canopy. (ref. diagram3). Diagram: 3 - CLEAN & DRY INSTALLATION AREAS 3 MARK A LINE USING THE BOTTOM EDGE OF THE RADIUS & EXTEND TO EDGE OF BED LINER REMOVE & RETAIN BED LINER & ALL HARDWARE 4 CUT-OUT MARKED AREA OF BED LINER MARK A LINE USING THE EXISTING EDGE RIGHT HAND SIDE OF BED LINER 4. For RX vehicle s only, with a genuine under rail bed liner fitted. Carefully remove the bed liner. Mark out the bed liner using the existing edge and bottom of radius as shown. Cut out the marked area on the bed liner. Remove all sharp edges and burrs. Repeat process for the other side. Do Not re-install the bed liner at this stage. (ref. diagram4). FRONT OF BED LINER Diagram: 4 - MARK & CUT-OUT BED LINER APPLY PRIMER STICK TO SHADED AREA ALONG FRONT RAIL FRONT RAIL TAPE 3 POSITION TAPE AGAINST SIDE RAIL Diagram: 5 - FIT 3M TAPE x700mm FRONT RAIL OF VEHICLE TUB SIDE RAIL OF VEHICLE TUB FRONT RAIL 4 APPLY DOUBLE SIDED x700mm ROLL (TAPE065) ACROSS FRONT RAIL 5. Using alcohol wipe provided clean the highlighted face of the front rail and wipe away residue with a dry clean cloth. If heavy cleaning is required use Iso- Propyl Alcohol and wipe away residue with a dry clean cloth. Apply (MISC365) primer stick to highlighted surface and allow to dry. Starting with a small amount of the tape from the double sided tape roll mm wide (TAPE065), apply it starting from the corner of the front rail of the tub to the other side, along the centre of the front tub rail pressing down on the liner as you apply the tape across the vehicle as shown. Apply firm pressure to ensure the tape adheres to the vehicle. IMPORTANT: Ensure the tape sits flat and DOES NOT pucker. (ref. diagram5). Page 9 of

10 VEHICLE CABIN NOT SHOWN FOR CLARITY CUT LABEL STICKER IN HALF 3 FIT LABEL STICKER FRONT RAIL UPPER HOLE IN SIDE PANEL LOWER HOLE IN SIDE PANEL 6. For RX vehicle s only. If the bare metal areas left from removing the cabin guard have not been painted, complete this step to fit the label sticker. Using alcohol wipe provided, clean the bare metal area around the lower hole on the side panel where the cabin guard hardware was removed and wipe away residue with a dry clean cloth. Cut black label sticker (LABL44) in half as shown. Remove adhesive liner from label sticker and adhere over the hole and bare metal surface on the side panel as shown. Repeat process for the other side of the vehicle. (ref. diagram6). Diagram: 6 - RX - FIT TUB STOP & RE-INFORCEMENT BRACKETS 5mm 5mm 9Nm 7 TIGHTEN ALL TEN (0) BOLTS TO TORQUE 9Nm M8 SPRING WASHER 5 M8x5 HEX BOLT M8 FLAT WASHER POSITION TUB STOP EXTRUSION (ALUM0038-0) LOOSELY FIT (4) RETAINED CABIN GUARD BOLTS 3 FIT LH/RH RE-INFORCEMENT BRACKETS (CNPY007PC-LH & CNPY007PC-RH) M8 FLAT WASHER CROSS SECTION THROUGH FRONT RAIL & RE-INFORCEMENT BRKT TAPE TUB STOP EXTRUSION RE-INFORCEMENT BRACKET 5 M8 FLAT WASHER M8 HEX NUT RETAINED CABIN GUARD BOLT M8x5 HEX BOLT FRONT RAIL 4 M8 SPRING WASHER 6 7. For RX vehicle s only. Position the front tub stop extrusion (ALUM0038-0) on the front tub rail and secure loosely using previously retained cabin guard bolts through the four (4) middle slots as shown. Fit LH/RH re-inforcement brackets (CNPY007) to the front tub stop extrusion and secure loosely using one () retained cabin guard bolt, M8 spring washer and M8 flat washer through the inboard slot, one () M8x5 hex bolt, M8 spring washer, two () M8 flat washers and one () M8 hex nut through the outboard slot, and one () M8x5 hex bolt, M8 spring washer and M8 flat washer through the slot in the side of the bracket into the side panel as shown (for both sides). Centre front tub stop extrusion to tub, and align the top face of the front tub stop extrusion to the top of the front tub rail and tighten all ten (0) bolts to Torque 9Nm. Re-install bed liner if removed previously. (ref. diagram7). Diagram: 7 - RX - FIT TUB STOP & RE-INFORCEMENT BRACKETS Page 0 of

11 5mm 5 5mm NOT SUPPLIED 9Nm M8 HEX NUT 4 M8 FLAT WASHER 4 M8x5 HEX BOLT REMOVE & DISCARD (8) PLASTIC CAPS 3 3 FRONT TUB SPACER EXTRUSION 5 CROSS SECTION THROUGH FRONT RAIL TAPE TUB STOP POSITION TUB STOP EXTRUSION (ALUM0038-0) M8 SPRING WASHER M8 FLAT WASHER Diagram: 8 - ST - FIT TUB STOP 3 4 MEASURE & MARK CENTRE LINE OF TUB SPACER = = FRONT RAIL TIGHTEN ALL EIGHT (8) BOLTS TO TORQUE 9Nm MEASURE & MARK CENTRE LINE OF FRONT TUB STOP 5 APPLY 0mm BEAD OF SILICON For ST vehicle s only Along the inside front face of the front rail remove and discard the eight (8) plastic caps. Position the front tub stop extrusion (ALUM0038-0) on the front tub rail and secure loosely using six (6) M8x5 hex bolts, M8 spring washers and M8 flat washers through the six (6) middle slots. Fit two () M8x5 hex bolts, M8 spring washers four (4) M8 flat washers and two () M8 hex nuts through the outboard slots as shown. Centre front tub stop extrusion to tub, and align the top face of the front tub stop extrusion to the top of the front tub rail and tighten all eight (8) bolts to Torque 9Nm. (ref. diagram8). 9. Use alcohol wipes provided clean the tape contact surfaces of the front tub spacer extrusion (ALUM0038-9) and wipe away residue with a dry clean cloth. Apply (MISC365) primer stick to highlighted area on extrusion and allow it to dry. Using a non permanent marker, measure and mark a line at the centre of the tub spacer (ALUM0038-9) and the centre of the front tub stop extrusion (ALUM0038-0) as shown. Apply a 0mm bead of non-acetic silicon (neutral cure), (not supplied) to the tub spacer on the short face between the two () grooves as shown. (ref. diagram9). Diagram: 9 - APPLY SILICON TO THE TUB SPACER Page of REMOVE TAPE LINER CROSS SECTION THROUGH FRONT RAIL SILICON TUB STOP TUB TAPE SPACER FRONT RAIL FIT FRONT TUB SPACER EXTRUSION 3 APPLY FIRM PRESSURE TO ADHERE TAPE Diagram: 0 - FIT RAIL EXTRUSION SPACER 0. Remove the liner film from the double sided tape applied to the front tub rail. Fit rail extrusion spacer(alum0038-9) to the front rail over the tape aligning the previously marked centre lines. Apply firm pressure rearward and down on the front tub spacer extrusion along the length to ensure maximum adhesion of the foam tape. Clean any excess silicon off using isopropyl alcohol. IMPORTANT: There must be NO silicon residue left on the top of the side bed rail faces, or the bed rail foam tape will not adhere correctly and water leaks will occur. Ensure no silicon is squeezed up by the fitting of the front tub spacer extrusion, if it is clean it off with IPA on a rag heavily loaded. (ref. diagram0).

12 . Using alcohol wipes provided clean all top rail areas of the tub and wipe away residue with a dry clean cloth. If heavy cleaning is required use Iso-Propyl alcohol and wipe away residue with a dry clean cloth Using priming stick (MISC365) prime top rails of the tub where EPDM foam tape will be applied in (step ). Please do not prime too far over the sides of the top rails, read (step ) to understand where the foam tape is to be positioned and use this as a guide for priming the area. Follow the instructions on the priming stick for optimum results. (ref. diagram). Diagram: - VEHICLE SURFACE PREPARATION NOT SUPPLIED 30mm TAILGATE OF VEHICLE TRIM SQUARE TRIM EXCESS SQUARE 30mm REARWARD OF TAILGATE STOP POSITION EPDM FOAM TAPE 5mm OUTBOARD OF THE INSIDE EDGE ALONG THE SIDE RAILS 5mm ALONG SIDE RAILS TOP VIEW OF VEHICLE TUB APPLY EPDM FOAM TAPE AROUND BED RAIL POSITION EPDM FOAM TAPE 5mm FROM THE FRONT EDGE OF THE FRONT TUB SPACER EXTRUSION 5mm ALONG FRONT RAIL WITH SPACER CABIN OF VEHICLE. Apply EPDM foam tape (TAPE0386) from hardware kit to the bed rails and spacer. Trim end of tape at 45 (0mm x 0mm) to align with marks on the tub rail as shown. IMPORTANT: DO NOT CUT FOAM TAPE! Trim one end of the foam tape square. Starting from one side at the rear corner, position the tape end 30mm rearward of the tailgate stop and 5mm outboard of the inside edge and continue this position all the way along the side rail in one continuous length. Position tape 5mm from the front edge of the front tub spacer and apply tape down the other side rail 5mm outboard of the inside edge to the end of the side rail. IMPORTANT: As the tape bends around the corners ensure the tape sits flat and DOES NOT pucker. Trim off excess square, 30mm rearward of the tailgate stop as shown. Ensure all foam tape areas are fully adhered to the tub and spacer by applying moderate pressure down on the tape all the way around the tub. (ref. diagram). Tape MUST be fully adhered to tub rails and spacer and sit flat in one continuous length to prevent water entering the canopy. FOAM TAPE MUST NOT PUCKER AROUND CORNERS 5mm 30mm ALONG SIDE RAILS Diagram: - INSTALL WATER SEALING TAPE Page of

13 NOT SUPPLIED TOP VIEW FRONT LEFT TUB CORNER APPLY NON ACETIC SILICON (NEUTRAL CURE) FRONT TUB SPACER EPDM FOAM TAPE FRONT TUB STOP INTERNAL VIEW INSIDE THE TUB EPDM FOAM TAPE FRONT TUB STOP APPLY NON ACETIC SILICON (NEUTRAL CURE) 3. With a clean cloth wipe down all areas of the internal front tub corners to be siliconed as shown. Spray areas to be siliconed with water, Do Not dry. Apply non-acetic silicon (neutral cure) (not supplied) to the top of the tub and spacer around the foam tape and inside the tub at the join between the front and side panels, ensure all gaps are silicon sealed properly. Re-spray silicon with water and push silicon into gaps and clean up excess silicon. Repeat process for the other side of the vehicle. IMPORTANT: This step must be done properly to ensure the vehicle tub is water sealed. (ref. diagram3). Diagram: 3 - APPLY SILICON NOT SUPPLIED VEHICLE CABIN NOT SHOWN FOR CLARITY FRONT TUB SPACER DOWN AT LEAST THE DEPTH OF THE RETURN OF THE FRONT TUB SPACER EXTRUSION FROM THE TOP OF THE TUB FRONT TUB SPACER SHEETMETAL SIDE RAIL Diagram: 4 - APPLY SILICON TOP VIEW OF TUB FRONT CORNER APPLY 0mm MASKING TAPE APPLY EPDM FOAM NON ACETIC TAPE SILICON (NEUTRAL CURE) 70mm SILICON SEAL GAPS IN THE CORNER OF TUB AT TOP 3 MARK LINES CLEAN FRONT RX 4mm 70mm ST 0mm ST-X 7mm With a clean cloth wipe down all areas to be siliconed as shown. Spray areas to be siliconed with water, Do Not dry. Apply non-acetic silicon (neutral cure) (not supplied) to the top of the tub and spacer around the foam tape and down the front side of the tub between the tub and the cabin, and down at least the depth of the return of the front tub spacer extrusion, from the top of the tub and push silicon into gaps. Run a 0mm bead of silicon on top of the EPDM foam tape in the centre, around the corners for a length of 70mm each way as shown. Repeat process for the other side of the vehicle. Also check from inside and outside of the front corners near the top of the tub and silicon seal gaps in the tub sheetmetal. IMPORTANT: This step must be done properly to ensure the vehicle tub is water sealed. (ref. diagram4). Clean front of canopy including the front window. Apply a length of masking tape to the front tub spacer (ALUM0038-9) for a length of 0mm and leave a length that is accessible over the edge of the vehicle to assist in removing when the canopy has been aligned. Using a non-permanent marker, measure and mark lines rearward from the front edge of the front tub spacer as shown. RX vehicle s - 4mm ST vehicle s - 0mm ST-X vehicle s - 7mm Repeat process for the other side of the vehicle. (ref. diagram5). Diagram: 5 - PREPARE Page 3 of

14 DO NOT SLIDE ON EPDM FOAM TAPE TAPE AND SILICON WIRING HARNESS TO RH SIDE WINDOW FIT TO VEHICLE HARNESS 3 FEED HARNESS BETWEEN TUB AND CABIN DOWN TO CHASSIS RAIL 6. Two people (minimum) are required for this step. First tape the wiring harness to the RH side window with masking tape. Position the canopy onto the vehicle tub carefully. IMPORTANT: Ensure canopy is placed fully forward on the tub in one action. DO NOT slide the canopy on the EPDM foam tape and silicon, as this can damage the foam tape and spread the silicon (break the water seal). Remove masking tape and feed canopy harness down between tub and cabin (right hand side of vehicle) so it is accessible under the vehicle on the outside of the chassis rail. (ref. diagram6). Diagram: 6 - FIT TO TUB VIEW FROM REAR OF CAR BASE RAIL EVEN BOTH SIDES AT THE END CAPS RULER VERTICAL AT LINE MARKED IN STEP 4. Diagram: 7 - ALIGN TO TUB 0mm RX=4mm, ST=0mm, ST-X=7mm FROM FRONT TUB SPACER TO VERTICAL RULER 7. Align the canopy evenly on the tub. The canopy lower perimeter extrusion s front face, should align with lines marked previously on the masking tape applied to the front tub spacer using a straight edge. RX vehicle s - 4mm ST vehicle s - 0mm ST-X vehicle s - 7mm Open rear door to check sideways alignment. Using a steel ruler position the canopy so both canopy base side rails are even to the width of the vehicle tub. From inside the canopy, also check the front holes in the front rail of the canopy align to the centre of the holes in the tub spacer extrusion. Remove masking tape from front tub spacer. (ref. diagram7). ORIENT SO THE LONG EDGE RUNS THE LENGTH OF THE VEHICLE FIT 6 CLEAR TAPE 50x3mm ABRASION RESISTANT TO TUB RAILS DIRECTLY UNDER CLAMP HOLES IN BASE RAILS 8. Fit six (6) clear tape 50x3mm abrasion resistant (TAPE00), to the vehicle tub rails directly under the square holes in the canopy base rails for the clamps as shown. Orient the tape so the long edge runs the length of the vehicle as shown. Position half of the tape on the front face of the rail and fold the remaining half around onto the back of the rail. (ref. diagram8). Diagram: 8 - FIT CLEAR ABRASION TAPE TO TUB Page 4 of

15 3mm 3mm DISASSEMBLE CLAMPS 9Nm 4 3 FIT & SLIDE BOTTOM U CLAMP LOCTITE 77 FIT TOP L CLAMP 4 APPLY LOCTITE 77 TO BOLTS, FIT BOLT & WASHERS TORQUE TO 8Nm 6 CLOSE REAR DOOR & CHECK LATCHES ENGAGE 7 READJUST LATCH STRIKER POSITION (IF REQUIRED) 5 REMOVE & RETAIN KEYS ATTACHED TO INTERIOR REAR DOOR HANDLE 9. Disassemble two () rail clamps. Fit the clamps to the rear holes in the canopy base rails by fitting the top L clamp down through the hole in the rail and sliding the lower U clamp along the side rail over the clear abrasion tape. IMPORTANT! Apply Loctite 77 (not supplied) to the bolts liberally. Secure the clamps with the bolts and washers as shown. Tighten to Torque 8Nm. Remove and retain the keys attached to the interior rear door handle. Close the rear door firmly, holding the centre handle without slamming it too hard. NOTE: Latch has stages of engagement. Ensure canopy engages with second stage of latch and the lower rear door seal, seals against the tailgate on the car. (ref. diagram9). Diagram: 9 - FIT REAR CLAMPS AND CHECK LATCHING 3mm LOCTITE 77 3mm DISASSEMBLE 4 CLAMPS 9Nm 4 TIGHTEN - FRONT CLAMPS TORQUE TO 9Nm FIT REMAINING CLAMPS APPLY LOCTITE 77 TO BOLTS 5 TIGHTEN - MIDDLE CLAMPS TORQUE TO 9Nm 3 TIGHTEN - REAR CLAMPS TORQUE TO 9Nm 30. Disassemble remaining four (4) rail clamps. Fit the clamps to the remaining holes in the canopy base rails by fitting the top L clamp down through the hole in the rail and sliding the lower U clamp along the side rail over the clear abrasion tape. IMPORTANT! Apply Loctite 77 (not supplied) to the bolts liberally. Secure the clamps with the bolts and washers as shown. Tighten the rear clamps first, then the front clamps and finally the middle clamps, all to Torque 9Nm. (ref. diagram30). Diagram: 30 - FIT REMAINING CLAMPS AND TIGHTEN ALL 0mm 0mm 6Nm 3 SECURE NYLOC NUT AND WASHER FIT BOLT AND WASHER BASE RAIL AT FRONT NYLOC NUT BOLT FIT / SECURE FRONT RAIL TUB STOP WASHER TIGHTEN TO TORQUE 6Nm VEHICLE FRONT TUB SHEET METAL Diagram: 3 - FIT / SECURE - FRONT TUB STOP RAIL 3. For ST-X vehicle s only. Fit front rail tub stop extrusion (ALUM0038-0) to the under side of the canopy front base rail and front tub spacer. Push extrusion up against the front of the tub and secure with four (4) M6 hex head bolts, eight (8) flat washers and four (4) nyloc nuts as shown. Tighten to Torque 6Nm. For RX & ST vehicle s only. Secure previously installed front rail tub stop extrusion (ALUM0038-0) to the canopy front base rail and front tub spacer using four (4) M6 hex head bolts, eight (8) flat washers and four (4) nyloc nuts as shown. Tighten to Torque 6Nm. (ref. diagram3). Page 5 of

16 3 4 Ø5mm Rust Inhibitor (x8) TOP GROOVE ON FRONT RAIL TUB STOP BOTTOM GROOVE ON FRONT RAIL TUB STOP 3. For ST-X vehicle s only Mark and drill eight (8) Ø5mm holes into the front rail tub stop and tub rail using dimension s as shown. Rivets must secure to flat form on tub. Apply rust inhibitor (MISC776) to all drilled holes in the tub sheet metal. Secure with eight (8) stainless steel rivets as shown. (ref. diagram3) Diagram: 3 - SECURE FRONT TUB STOP RAIL REAR WINDOW REAR DOOR SASH APPLY MASKING TAPE TO TAILGATE 33. With the canopy rear door closed, apply a length of masking tape either side of the plastic infill panel to the rear tailgate, level with the bottom edge of the canopy rear door sash, when viewed from the rear horizontal position as shown. This will assist in positioning the clear abrasion tape applied to the top of the tailgate in the next step. (ref. diagram33). MASKING TAPE TAILGATE Diagram: 33 - APPLY MASKING TAPE CLEAR ABRASION TAPE 5% ISOPROPYL ALCOHOL 75% WATER Page 6 of CUT CLEAR ABRASION TAPE INTO TWO EQUAL HALVES 3 APPLY CLEAR ABRASION TAPE ALIGN BOTTOM EDGE OF CLEAR ABRASION TAPE WITH TOP EDGE OF MASKING TAPE 5 SQUEEGEE OUT EXCESS SOLUTION 4 TRIM BUBBLES EXCESS CLEAR ABRASION TAPE 6 REMOVE MASKING TAPE NOT SHOWN FOR CLARITY Diagram: 34 - APPLY ABRASION TAPE 34. Unroll and cut abrasion tape (TAPE06-) into two equal halves. Using a solution of 5% 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, place liner on the tailgate. Trim excess tape leaving a 5mm overhang at plastic infill panel. When in position use a squeegee to push out any excess water solution and bubbles. Using a sharp knife or scissors trim tape to end of tailgate & infill panel. You may need to squeegee a few times. When finished the tape is virtually invisible. Repeat for the other side. To ensure a good finish please take care an do not rush this step. Remove masking tape. (ref. diagram34).

17 BULB SEAL FINGER UNDER CLAMP SEAL & AGAINST FINGER NISSAN NAVARA D40 - ALCOHOL WIPE & PRIME SHADED AREA CROSS SECTION OF SEAL TAILGATE BULB SEAL SIDE TUB RAIL 3 FIT BULB SEAL CLAMP FRAME SEAL TAILGATE 35. (OPTIONAL): Strongly Recommended for best results for rear door to tailgate water sealing. Using alcohol wipe provided clean directly below the rear door clamp front seal and wipe away residue with a dry clean cloth. Using priming stick (MISC365) prime area directly below the rear door clamp front seal. Apply only a light amount both sides of tailgate in this area, and allow to dry. Apply bulb seal 70mm (MISC600-) to tailgate. Position bulb seal so it's finger seals against the underside of the clamp frame seal after the bulb on the clamp frame seal as shown and position it in line with the outer edge of the tailgate as shown. (ref. diagram35). Diagram: 35 - (OPTIONAL) FIT TAILGATE SEALS CONNECT HARNESS TO VEHICLE HARNESS 36. Feed the canopy harness down to the vehicle harness on the chassis rail. Connect the canopy harness connector to the vehicle harness connector as shown. IMPORTANT: Wiring harnesses should be positioned away from the exhaust system side. (ref. diagram36). CHASSIS RAIL Diagram: 36 - CONNECT VEHICLE & CONNECTORS 37. Two people are required to check the canopy brake light is operational after depressing the brake pedal. Then open the rear window and check that the internal canopy lamp is operating correctly when switched to the ON position only. NOTE: An additional accessory can be ordered from EGR to turn the light on in DOOR position of the switch when the door is opened automatically. (ref. diagram37). CHECK BRAKE LIGHTS WORK CHECK LAMP WORKS Diagram: 37 - CHECK BRAKE LIGHTS AND LIGHT Page 7 of

18 CABIN TUB SPACER 38. Using alcohol wipe provided in the kit, clean the driver s side, front face of the front tub panel as shown, and wipe away residue with a dry clean cloth. Remove tape liner from adhesive tie pad and position on the front tub panel in area previously cleaned as shown. Apply pressure to ensure maximum adhesion. (ref. diagram38). TUB FIT ADHESIVE TIE PAD TO FRONT TUB PANEL Diagram: 38 - FIT ADHESIVE TIE PAD CABIN TUB SPACER 39. Fit one () short cable tie through the adhesive tie pad previously fitted to the front of the tub and secure the canopy wiring harness as shown. Trim excess tie with side cutters. (ref. diagram39). TUB FIT CABLE TIE Diagram: 39 - SECURE HARNESS ANTI-CLOCKWISE = LENGTHEN 3 ADJUST LENGTH DETAILS TO ADJUST PULLRODS OF PULLRODS BY ROTATION REMOVE INTERIOR LOCK COVER 6 REPLACE INTERIOR LOCK COVER 4 RE-CHECK LOCK FUNCTION 40. Water test canopy checking for water leaks. Test both canopy keys work to lock and unlock the rear door and side lift up window. Open both side windows. If the rear door handle does not lock, remove the interior lock cover, unclip the pull rods and wind to lengthen them slightly. Re-check rear door lock function. When rear door locks replace interior lock cover, and add the canopy keys to the customers vehicle keys. (ref. diagram40). UNCLIP PULLRODS FROM RETAINER CLIPS 5 CLIP PULLRODS INTO RETAINER CLIPS Diagram: 40 - WATER LEAK TESTING Page 8 of

19 PLACE FITTING INSTRUCTIONS IN THE CUSTOMERS LOG BOOK 4. Clean canopy including all windows and vehicle thoroughly. Place fitting instructions in the Customers log book, and ensure page 0 of these instructions are discussed with the customer and a copy is given to the customer. (ref. diagram4). Diagram: 4 - FINAL CLEANING Page 9 of

20 OWNERS MANUAL SUPPLEMENT IMPORTANT: PLACE THIS PAGE IN THE CUSTOMER S VEHICLE SERVICE BOOK. WARNING! - SAFETY! Do Not use the canopy as a passenger compartment. Do Not operate/drive vehicle with fold up windows or rear door open. They must be closed when vehicle is in motion. Do Not store or transport volatile materials, such as solvents, chemicals or liquids as fumes may accumulate inside canopy. Do Not allow solvents, chemicals or oils to come in contact with the canopy. If this should occur clean the canopy immediately with a mild detergent and water solution. Do not stand/sit or rest heavy objects on Canopy. Do not fill volatile liquid containers while inside canopy such as fuel cans. VEHICLES FITTED WITH A BED LINER: Static electricity can cause fire when fuel is pumped into ungrounded fuel containers or equipment (eg: motorcycles, chainsaws etc..). Do Not fill fuel containers or equipment within the vehicle tray as static electricity can cause fuel to ignite, resulting in damage, injury or death. To avoid electricity build-up, place fuel container or equipment on the ground before filling. Maintenance Only use mild detergents or wax polish. Do Not use abrasive compounds on painted or plastic finished canopy surfaces. The gas struts are self lubricating and should only be cleaned with a damp cloth, when regularly cleaning the vehicle. Premature seal failure will result if solvents or lubricants are used to clean struts. Gas struts must be orientated as installed, cylinder (wide end) to canopy and rod (narrow end) to glass. Lightly coat the door and window rubber assemblies with a silicon spray after cleaning periodically. Only locks and lock recesses are to be lubricated with Graphite Powder. Vaseline may be used on the rotary catches on the rear door. DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty. Check canopy attachment clamps every 000 Km. Clamp bolt recommended torque setting is (9 Nm or 6.64 lb/ft). If removed, bolts must have LOCTITE 77 re-applied and be re-tightened on refitting to specified values. CHECK regularly that all screws and fasteners holding windows and doors are tight. The rear tailgate protection tape must be replaced periodically to minimize paint scuffing caused by the canopy rear door opening and closing. For sliding windows use a silicon based Non-Aerosol lubricant or a dry film lubricant or LY70 lubricant or 3M window channel dresser lubricant sparingly. DO NOT use CRC, WD40 or petroleum based lubricants on sliding windows. Nissan Navara D40 KEY IDENTIFICATION CODE 34 Please write the key identification code in the boxes above, and retain this copy with the vehicle service history. Replacement keys can be purchased from your local dealer. Warranty Terms - EGR warrants that the ABS Canopy will be free from defects in material and workmanship for a period of three (3) years from the retail date of purchase. The gas struts are warranted for one () year from the retail date of purchase. This warranty only applies to the original purchaser and is nontransferable. Warranty must be claimed with original sales receipt for proof of purchase. Exclusions - This warranty does not cover failure due to neglect, improper installation, including any modifications to installation hardware, alterations, addition of non genuine equipment, abuse, accident, normal wear and tear, lack of maintenance, misuse, and exposure to chemicals that are not safe for plastics or hardware components. Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Canopy is sole responsibility of the vehicle owner and operator. Paint wear to the vehicle bed can happen with any Canopy and is the sole responsibility of the vehicle owner. Paint damage to your vehicle is not covered under this warranty. Disclaimer - In the event that your EGR Canopy is found to be defective under the terms of this warranty, it is at the discretion of EGR to repair or replace the defective part. Transportation costs and labour are not associated with this warranty claim. Page 0 of

21 INSTALLATION CHECKLIST Dealer Name: Model: Order Date: Required By: Dealer Code: Stock No: Order No: Vin No: Canopy Colour Vehicle Damage Check: Detail: Vehicle Type: RX 4x RX 4x4 ST 4x4 ST-X 4x4 Canopy Checklist - Details of rectifications required: KEY No. :. Check paint on canopy. Cleanliness of canopy inside and outside 3. Canopy sealing to tray, tub spacer rail, tub stop rail and foam tape applied correctly 4. Seal around Front of tub, vertical corners & floor with Silicone after foam tape applied 5. Tailgate clear tape fitted 6. Position canopy on tub squarely side to side, rear door closes on second stage latch (not just first latch) both sides and lower door sash seal, seals to tailgate, adjust strikers and /or door latch pull rods via access to centre door handle by removing internal door handle cover 7. Clamps are square and tight (Torque 9Nm) 8. IMPORTANT! Loctite 77 applied to all Clamp Bolt Threads 9. Rear Door, Side Door s and Front window operation, side windows lock with keys. Check rear door handle and locks with keys. If not locking remove interior cover on rear door handle and adjust the pull rods by winding them in/out and test the door again, replace cover. 0. Operation of Brake Light. Operation of interior light. Water Tested for leaks 3. Clean up of work area 4. Comment Fitted By: Vehicle received and Checked by Dealer Staff: Record Canopy Serial Number: (located on inside LH rear pillar of canopy shell) Checked By: Page of

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