FD1297
27OCT04
COPYRIGHT
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
FITTING INSTRUCTIONS FOR
RODEO SPACE CAB WITH SPORTS BAR
TONNEAU COVER
Page 1 of 5
TOOLS REQUIRED:
Drill, 4.5mm Drill Bit, Hi-tech Cleaning Pads (supplied), Measuring Tape, Felt Tip Pen (Recommended), Rivet Gun,
Corrosion Inhibitor, Vacuum Cleaner.
For tub liner removal: Phillips Head Screwdriver, 10mm Socket, Extension, Rachet, T40 Torx Bit, Allen Key 5 mm.
Part No. 92148820
FITTING INSTRUCTIONS:
NOTE: It is recommended that the vehicle is cleaned
before starting the procedure and any paint repairs are
performed and allowed to cure.
1. Mark points on both the inner side tray rails, 620mm and
1280mm from the front of the tray using a felt tip pen
(recommended). Refer to Figure 1.
FIGURE 1
620mm
MARK
(4 PLACES)
1280mm
FD1297
27OCT04
COPYRIGHT
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
FITTING INSTRUCTIONS FOR
RODEO SPACE CAB WITH SPORTS BAR
TONNEAU COVER
FITTING INSTRUCTIONS: - continued...
Refer to Figure 2 for the following:
2. At either mark on the inner side tray rails, place the bow-
saddle halfway across and halfway down the rail and
mark the saddle holes (2 places).
3. Drill holes (2 places) through the saddle hole marks
using a 4.5mm drill bit.
4. Vacuum up any swarf and apply corrosion inhibitor to the
holes. Allow time for inhibitor to dry.
5. Secure the saddle onto the inner side tray rail with the
supplied 18mm x 4 mm rivets (2 places).
NOTE: If a tub liner is fitted, perform this step last.
6. Repeat steps 2 to 5 for the other bow saddles.
Refer to Figure 3 for the following:
7. Align the rear of the tonneau cover centrally over the
tailgate ensuring that there is an equal distance between
the tailgate edges and the closest adjacent shock cord
loop from the tonneau cover.
NOTE: Ensure that tonneau cover is stretched across
the tailgate.
8. Mark using a felt tip pen (6 places) the locations of the
shock cord loops along the length of the tailgate.
9. Using the marks from the previous step as reference
points, measure downwards 120mm from the top of the
tail gate and mark using a felt tip pen (6 places). Remove
the tonneau cover from the vehicle.
10. Drill holes, 6 places, through each of the marks from the
previous step using a 4.5mm drill bit.
11. Vacuum up any swarf and apply corrosion inhibitor to the
holes. Allow time for inhibitor to dry.
12. Place a button against each of the drilled holes in the
tailgate and secure with supplied 18mm x 4mm rivets, 6
places.
Page 2 of 5
RIVET
(2 PLACES)
BOW SADDLE
EQUAL
FIGURE 2
FIGURE 3
120mm
SHOCK CORD
LOOP (6 PLACES)
BUTTON
(6 PLACES)
RIVET
(6 PLACES)
CENTRAL BUTTON
MARK (6 PLACES)
TONNEAU COVER
EQUAL
DISTANCE
FD1297
27OCT04
COPYRIGHT
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
FITTING INSTRUCTIONS FOR
RODEO SPACE CAB WITH SPORTS BAR
TONNEAU COVER
FITTING INSTRUCTIONS: - continued...
Refer to Figure 4 for the following:
13. Secure the front of the tonneau cover by fitting the plastic
clip over the leading edge reinforcement. Secure the
rear of the tonneau cover by placing the shock cord
loops around the six buttons.
14. From the rear of the side panel, using a felt tip pen mark
the position of the shock cord loops, excluding the
forward loop. Repeat on the other panel.
15. Using the marks from the previous step as reference
points, measure down 120mm from the top of the side
panel and mark using a felt tip pen, six places. Repeat
for other side. Remove tonneau cover from the vehicle.
16. Drill holes through each of the marks from the previous
step using a 4.5mm drill bit.
17. Vacuum up any swarf and apply corrosion inhibitor to the
holes. Allow time for inhibitor to dry.
18. Place a button against the drilled holes in the side panels
and secure with supplied 18mm x 4mm rivets, six
places, for each side panel.
Refer to Figure 5 for the following:
19. Mark a point 30mm from the front and 85mm from the
top using a felt tip pen, for each side panel.
20. Drill a hole through each of the marks from the previous
step using a 4.5mm drill bit.
21. Vacuum up any swarf and apply corrosion inhibitor to the
holes. Allow time for inhibitor to dry.
22. Place a button against drilled holes and secure with
supplied 18mm x 4mm rivets.
23. Clean off all marks made during fitting.
Page 3 of 5
85mm
30mm
FIGURE 5
FIGURE 4
120mm
FD1297
27OCT04
COPYRIGHT
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
FITTING INSTRUCTIONS FOR
RODEO SPACE CAB WITH SPORTS BAR
TONNEAU COVER
FITTING INSTRUCTIONS: - continued...
24. Remove the tailgate liner, if fitted, and where necessary
flex the tub liner away from the body. This will be made
easier by removing the fasteners at the rear of the liner.
25. Use the hi-tech cleaning pad (1) (supplied) to clean the
side of the vehicle above the tie-down positions where
the tonneau contacts the vehicle body. Refer to Figure 6.
26. Remove the backing with writing on (1) from the
patch (2). Leave the covering on the patch. Refer to
Figure 7.
27. Position the patch (1) vertically above the tie-down point
so that it straddles the upper body contour line and the
top of the tray. Refer to Figure 8.
NOTE: The centre of the patch should coincide with the
corresponding bungy hard fixing point on the tonneau
cover.
28. To prevent air becoming trapped under the patch, place
one edge of the patch onto the vehicle. Working from the
edge to the other side, rub the patch down. Refer to
Figure 9.
FIGURE 6
FIGURE 8
FIGURE 7
1
2
1
1
FIGURE 9
1
Page 4 of 5
FD1297
27OCT04
COPYRIGHT
Reproduction in whole or part
prohibited without written approval
HOLDEN LTD
Division of HOLDEN Ltd ACN 006 893 232
FITTING INSTRUCTIONS FOR
RODEO SPACE CAB WITH SPORTS BAR
TONNEAU COVER
FIGURE 10
FITTING INSTRUCTIONS: - continued...
29. Remove the covering from the patch. Refer to Figure 10.
30. Repeat on all locations.
31. Refit liner (if required) and fit the tonneau cover.
32. Place fitting instructions in glovebox.
1
PARTS LIST
Page 5 of 5
PART NUMBER DESCRIPTION QUANTITY
92148819 SOFT TONNEAU COVER PACKAGE 1
BOW - SADDLE 4
BOW - 1450mm 2
RIVET - 18mm Long X 4mm DIA 28
BUTTON - BLACK 20
92148810 PROTECTIVE TAPE KIT 1
SELF ADHESIVE PATCH 20
HI-TECH CLEANING PAD 1
FD1296 FITTING INSTRUCTIONS 1
FD796 PROOF OF WARRANTY CARD 1