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Part Number: 206L TUFF LID INSTALLATION INSTRUCTIONS Holden Commodore VG VP VR VS 1990 to Feb 2001 Part number: 206L Package includes 3 X Medium Locking Brackets (300654) 6 X 22mm Screws & 5mm S/Washers 2 X Threaded Strut Balls (300650) 2 X 250N Gas Struts (300639) 5 X 8mm Flat Washers (300485) 5 X 8mm Spring Washers (S-0053) 1 X 2m Length of Foam Tape 2 X Keyrings (300492) 2 X #4 Female Hinges (S-0074) 3 X 8mm Bolts (300483) 6 X Flat Washers (300486) Contents 1. BEFORE FITTING ....................................................................................................................... 2 2. TUFF LID FITTING INSTALLATION PROCEDURE ....................................................................... 2 2.1 BASIC TOOL REQUIRED .......................................................................................................... 2 2.2 INSTALLATION PROCEDURE ................................................................................................... 2 2.3 CUSTOMER USER SHEET ........................................................................................................ 5 1 | P a g e 1. BEFORE FITTING Ensure that your Tuff lid’s fitting kit is complete and your keys open the new lock. Please read fitting instructions carefully and completely before attempting to fit your new lid. If any parts are missing, do not return product to place of purchase. Instead, call our toll free customer care line on 1800 656 820 for replacement parts within two working days. 2. TUFF LID FITTING INSTALLATION PROCEDURE IF THE UTE HAS A UTELINER: The Tuff lid should be compatible with most brands of Ute liners. The hinges must always be fitted first, directly onto the vehicle body. The hinges should never be fitted over the Ute liner. The Ute liner will need to be cut out so that it fits around the hinges, some model Ute liners might fit better with the section across the front (between and to the sides of the hinges) removed. The gas strut balls, side and rear lock brackets will need to be screwed through the liner. 2.1 BASIC TOOL REQUIRED Drill, Phillips Head Drill Bit, Tape Measure, Marking Pencil/Pen, Silicone 2.2 INSTALLATION PROCEDURE Step 1: Find and mark the middle of the tray at the front, measure out 475mm towards the driver side of the vehicle and make a mark. Repeat this procedure on the passenger side. Align the centre of the female hinges with your marks and attach with self-drilling screws, spring and flat washers supplied (3 per hinge in triangle pattern). Do not over tighten screws, as the metal can be fairly thin on some models. See Figure 1 Step 2: We recommend that you now remove the hinges so that you can clean away any swarf or metal filings and apply a bead of silicon to the underside of the hinges and the 6 holes that you have drilled to prevent water seepage, and then refit the hinges. 2 | P a g e Step 3: Now apply the foam tape supplied between and past the two hinges already fitted to the vehicle. Stop at the hinge and then start again on the other side of the hinge and continue around the corner finishing at the cars edge. Ensure that where the foam tape meets the hinge and the edge that you have a good tight join. You can apply a small bead of silicon at these joins to ensure that you have an uninterrupted seal from side to side. Note: If installing in cold weather the foam tape may need be heated to assist adhesion. See Figure 1 Step 4: Locate and remove the Allen head screw, which is to the front of the original tonneau cover bar bracket, using 5mm Allen head key. Using the factory hole as a centre point, attach the gas strut brackets using 22mm screws with spring washers. See Figure 2 Step 5: Take Tuff Lid and carefully lift vertically and insert hinge tongues on the lid into hinge slots on the vehicle. Carefully lower lid, ensuring that the tongues are fully inserted into the slots. Attach the cylinder end of the gas struts onto the brackets on the lid. Important, now attach the key ring to the small hole at the end of the male hinge. This prevents accidental release. The gas struts may be removed at any time by inserting a small screwdriver under the metal spring clip on the gas strut end and gently easing it out. You can then pop the strut off the ball. Never completely remove the spring from the gas strut end. Remember, when removing and refitting your Tuff lid ensure that the hinges are fully engaged to avoid damaging or bending them and the key ring’s are attached to each male hinge to avoid them releasing accidentally Step 6: Close the lid and check to see if the lid fits evenly around the side and the back. The Tuff Lid can be adjusted forward and back by loosening the screws on the male hinges, and sliding the hinge back or forward, retighten screws after adjustment. 3 | P a g e Step 7: To fit lock brackets remove the last Allen head screw on the top rails (both sides) and remove the centre one on the top of the tailgate. Install a lock bracket onto each hole with the bolts supplied allowing for adjustment up or down. You will also need to cut the locking rods to the correct length. Adjust the locking brackets to the right height so the lock cam arm fits snugly under the lock brackets. To do this for the side locking brackets just close the lid with the tailgate down so you can watch the locking action. See Figures 3 + 4 Close the tailgate and check to see if lid locks correctly. When correctly adjusted you should need to apply slight pressure to the lid in order to operate the key. NEVER DRIVE WITH LID OPEN OR IN AN UNLOCKED POSITION Having trouble? Call us toll free for assistance on 1800 656 802. 4 | P a g e 2.3 CUSTOMER USER SHEET *Please pass on for Owner / User Reference Using the Pop-up, T-Handle, ‘Tuff Lid’ Lock: Unlocking your lid: 1. Place the key in key hole 2. Turn the key Anti-clockwise 3. Remove the key and press firmly on the key hole 4. The T-Handle will automatically pop up when they key hole is pressed. Turn the handle and lift lid Locking your lid: 1. Turn the T-Handle back to it’s original position and push the handle down so it sits flush with the lid 2. Place the key in the key hole and turn clockwise Tonneau and Tuff Lid care information: All Tonneaus and Tuff Lids are not recommended to be used as a load restraint. For extra protection from weather and for a newer looking cover, we recommend to use ‘303 Protectant’ which is available from your local Autobarn store. 5 | P a g e .
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