D40C HINGE # x Support Plate x M8 Bolt 8 x M8 Washer 6 x M6 20mm Bolts 6 x M6 Washers 19 x Screws

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1 HINGE # x Support Plate x M8 Bolt 8 x M8 Washer 6 x M6 20mm Bolts 6 x M6 Washers 19 x Screws 2 x Lid mount gas strut bracket x Self tap strut mount x Central Lock bracket x Gas struts (250N) 1 x Plastic tube 500mm 1 x Wiring loom (Tonn Dual - 01) 5 x Zip ties 1 x Alcohol wipe 1 x Instruction manual 1 x FBA Bar Fitting kit made by : Page 1 of 15

2 Fitting Instructions Part Number Nissan D40 Navara Dual Cab Check contents of kit before commencing fitment and report any discrepancies Parts List Qty Pre-Fitted Hard Tonneau Cover 1 Gas Struts (250N) 2 Front Hinge 2 Hinge Support Plate 2 M8 Washer 8 M8 Bolt 8 Lock Bracket 2 Self Drilling Screw 13 Lid Strut Bracket 2 M6 Washer 6 M6 Bolt 6 Front Body Attach Bracket 2 Front Body Assembly Bar 1 Lock Set 2 Tonneau Corner Pieces 2 Cleanseal 1 *Image example shown only IMPORTANT Do not stand/sit or rest heavy objects on Tonneau Cover Humans or animals are not to be under the closed Tonneau at any given time Securely lock tonneau Cover before operating vehicle Tonneau Cover is not dust or water tight Do not carry open volatile chemicals with Tonneau Cover installed If contact with volatile chemicals occur, clean Tonneau with mild detergent and water solution Care Instructions Read Instructions fully before commencing installation. Clean Tonneau Cover with a mild detergent and water solution Do not use abrasive cleaners or solvents Refer to manufactures instructions applicable to power drill. Protect Tub floor against scratches during installation process. Maintenance If lubrication of the locks or hinges is required use only Graphite Powder. DO NOT use any other lubricants or oils. Tools Required Pen / Marker Die Grinder & multi tool Soapy water solution Centre Punch Masking Tape Allen Key set (Metric) Drill & Drill bits Scissors & Knife Phillips head screwdriver Ruler Caulking Gun Spanner & Socket Silicon - Non Acetic Tape measure Page 2 of 15

3 Installation Steps Flow Chart START TUB PREP FOR LID INSTALL LID INSTALL AND ADJUSTMENT WIRING FINISH Page 3 of 15

4 Thoroughly clean installation areas. Lay a sheet inside the tub to catch metal drill swarf from installation. Important: Instructions are for Utes with an UNDER-RAIL tubliner. If you have an OVER-RAIL tubliner you must trim the top off. The Front Bar Assembly (FBA) should be fitted first. The FBA will already have the hinges fitted to it. Align the bar along front of tray, ensuring ends of bar are flush with sides of tray. Remove white paper tape from rubber seal and attach the FBA using self-drilling screws (supplied) through holes pre-drilled in bar. Apply clear or black silicone to any gaps and between the FBA and the vehicle to prevent water entry. Page 4 of 15

5 Gas Struts: Hook tape measure over front edge of tub, measure along top edge of tray 1010 mm (windscreen end) then down 25mm and mark the screws position for the gas strut bracket. Position the gas strut bracket accordingly, mark two mounting holes and centre. Refer to Fig. 1 and Fig mm 25 mm Fig.1 - Gas strut bracket location Fig.2 - Gas strut bracket location Using a 2 mm diameter drill bit set to 5 mm drill stop. Drill two pilot holes. Attach small gas strut bracket using self drilling screws provided. Repeat process on other side of tray. Refer to Fig. 2 and Fig.3 Fig.3 - Gas strut bracket fitment Attach small shaft end of gas strut onto gas strut brackets, by clicking them in place. Refer to Fig.4 with regard to gas strut orientation. Fig.4 - Gas strut orientation With the lid on the floor and taking care to prevent damage or scratches to the painted surface, fit the upper gas strut mounting brackets to the lid using 20mm M6 Screws and Washers. Refer to Fig. 5 Fig. 5- Hard Cover strut bracket location Page 5 of 15

6 Important: DO NOT over tighten screws. Recommended tightening torque is 1-3 Nm With one person on each side, lift lid to the vertical position and insert the hinge tongues into the hinge slots on the front bar assembly. Refer to Fig. 6 and Fig. 7 Fig. 6 - Lift Lid near vertical and carefully slide hinge tongues into hinge slots. Fig. 7- Hard Cover strut bracket location Important: Ensure tongues are fully inserted into the hinge slots. 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. Page 6 of 15

7 With the Hard Tonneau Cover opened, attach the cylinder end of each gas strut onto the mounting brackets attached to the Hard Tonneau Cover by clicking into place. Refer to Fig. 9 Fig. 9 - Attach gas strut Important: If you have purchased a Central Locking Ute Lid please ignore the next page concerning Lock Bracket Installation and Lock Bracket adjustment. Page 7 of 15

8 Important: This page for Manual Locking lids ONLY Please skip this page if you have purchased a Central Locking Lid Lock Brackets: To fit lock brackets, open tailgate and close the Hard Tonneau Cover. Make a mark where the lock cam (arm) lines up with the sides of the tub. Open Hard Tonneau cover and locate the two pairs of bolts on either side of the tub near the tailgate. Remove the rear bolt and place striker hinge - aligning the middle hole with the bolt hole and re-bolt. Ensure that there is allowance for up and down adjustment of the bracket. Repeat on other side. Refer to Fig. 11 Fig Install lock bracket Close the Hard Tonneau Cover and try the locks. You may need to adjust the lock brackets on the Ute tub up or down. When correctly adjusted, you should need to apply slight pressure to the lid in order to operate the locks. Refer to Fig. 12. Fig Lock bracket adjustment Important: Excess tension could damage the lock. Page 8 of 15

9 NISSAN D40 CENTRAL LOCKING WIRING INSTRUCTIONS Part no:, D15C 240mm 185mm Measure 185 mm towards the centre from the top inside edge of tub and 240 mm down from top as shown above. At this point drill a 25 mm hole using a holesaw to go through the tubliner and the metal support behind as well only. Making sure the rear seat is folded down using a 10mm drill bit, drill in the centre of the hole made previously, drill right through the cab of the Ute and inner lining. The cable release will already be assembled as above. Take off black cable release handle,10 mm nut and the 15 mm nut with washer. Leave the last washer and nut as is. With the nut and washer in position feed the cable through the body making sure it comes out in the interior of the Ute cab. The lining covering of the rear panel of the cab (rear back rest of seat ) must be pulled down. As seen above now place a washer first through the cable followed by a gold 15mm nut, tighten the nut with a 15mm ratchet. Refit the lining to original position making sure the cable release end is coming out of the lining. Making sure the lining is not obstructing the cable release. Page 9 of 15

10 Finally tighten the 10mm gold nut on the end of the cable release followed by the black handle. Once the black handle is tightened all the way turn the 10mm gold nut tightened previously behind the handle anti-clockwise until it meets up with the inner tip of the black handle. Make sure the handle securely tightened. At this time it is best to engage the lock on the lid by pushing the lock lever up so it goes into lock position. Then pull on the cable release from inside the cab to ensure that the lock opens manually. Page 10 of 15

11 Feed the wiring loom through and in-between the tub and the cab from the hole made previously in the tub. Making sure when feeding the loom that the three wires which are the black, red and brown ends of the loom are fed through the hole, and not the end where the connector is part of the loom. Feed the red and black wire under the cab along the top of the right hand side chassis rail of the cab and up towards the battery. And connect the red wire to the Positive battery terminal and Black wire to the negative battery terminal. Page 11 of 15

12 Now you can connect the wiring loom connector of the vehicle to the connector of the ute lid. Page 12 of 15

13 On the driver side use the electric switch strut, fit the shaft end of the gas strut onto the ball on the ball plate. A CLICK will be heard when the strut is seated correctly. Allow the other end of the strut to lay on the wheelhouse. Connect the earth wiring harness to the terminal on the passenger side gas strut as shown. Once the strut is attached to the lid strut mount then you can connect the earth wire from the lid to the strut. Locate the central locking loom of the Ute, leading into the drivers door. Now locate the white with silver ring wire and attach the brown scotch clamp provided in the wiring installation kit. Page 13 of 15

14 The brown wire that was fed through the hole should now be attached to the brown scotch clamp. Making sure that the connection is made correctly. This is the signal used by the Lid to open the lock via central locking. Now re-attach kick panel, scuff plate and rubber door frame seal. Align the center hole of the latch with the top of the center of the tailgate. making sure the bottom of the latch is facing down. With the self drilling screw provided gently screw through so it is still able to move up and down. With the lid open now close the tailgate. Climb into the tub with a torch light and Phillips head screw driver, with the aid of another person now bring the lid down slowly. Once the lid lock catches the latch and is aligned, tighten the self drilling screw all the way and ask the other person to open the lock by pressing the open button on the factory key. If the lock from the lid is not matching correctly it is wise to open the black cover of the central locking unit and loosen the lock unit by opening the 6 screws half way and adjusting the lock to meet the latch on the tailgate to get the best result. Retighten the screws and replace the black cover making sure all wires are not obstructed. If the interior light of the lid is dim, this means that the tub of the Ute does not have a good earth. There is a 30mm long earth wire supplied in the kit which will have to be earthed between the chassis and the tub at the most relevant position to gain a better earth for a brighter light. Page 14 of 15

15 Gas Strut Terminal Adjustment for Interior Light. *Please Refer to this only if your interior light doesn t turn off correctly when Tonneau is closed. Loosen the screw found on the terminal housing on the electric gas strut, until it can move up and down the strut freely. With the tailgate open, gently close the Tonneau Cover. Inspect the gas strut and ensure the terminal housing has come into contact with the gas strut s cylinder as shown. Finally, open the Tonneau Cover and tighten the screw on the terminal housing as shown. Fig. 9 - Remove gas strut Important: To remove the Hard Tonneau Cover from the vehicle, detach the gas struts from the Hard Tonneau Cover. This is done by inserting a small screwdriver under the metal spring clip on the strut and easing it out sufficiently to allow the strut to be popped off the ball (Refer to Fig 9). From inside of tub, remove 4 bolts from each hinge bracket. Ensure someone is supporting the lid when detaching. Never completely remove the metal spring clip from the gas strut end, and never force the strut off the ball. Paint care instructions: Your new painted Hard Tonneau Cover has been covered with a plastic film to protect the paint from damage. It will require cleaning and possibly light polishing after the protective film has been removed. Use polish as per new paint on a new vehicle. Wash Hard Tonneau Cover using water and normal carwash detergent and polish with an automotive polish. NOTE: Please ensure Lid is kept locked at all times when not being used, for both safety and longevity. Having trouble? Call your Supplier. Page 15 of 15

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