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VEHICLE DESCRIPTION:
PLEASE KEEP INSTRUCTIONS IN GLOVE BOX FOR FURTHER USE
LIST OF PARTS
NO.
PART NAME
1
Tonneau Cover
2
Corner Piece LHS
3
Corner Piece RHS
4
Lock Striker Bracket
5
Gas Strut Bracket
6
Hinge Pin
7
M6x15mm Bolt
8
M6 Flat Washer
9
M6 Nut
10
Pop Rivet
1
2
11
12
21
22
Page 1 of 13
3 PC TONNEAU COVER
INSTALLATION INSTRUCTIONS
QTY
NO.
PART NAME
1
11
Bottom Hinge
1
12
Retainer Clip
1
13
Gas Strut
2
14
M8x50mm Bolt
2
15
M8 Nut
2
16
Lock Striker Support Bracket
8
17
Jacking Bracket
24
18
Extrusion Tape Roll
16
19
M6 Large Metal Washer
12
20
M6 Spring Washer
3
4
13
14
23
24
QTY
2
2
2
2
4
2
2
1
4
12
5
6
15
16
25
26
Mitsubishi L200
NO.
PART NAME
21
U Bolt
22
Rust Inhibitor
23
Alcohol Wipe
24
Keys
25
M6x40mm Bolt
26
Anti-Rub Pad
7
8
17
18
TC0194
QTY
2
1
3
2
4
2
9
10
19
20
17/11/09
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Summary of Contents for EGR TC0194
- Page 1 TC0194 3 PC TONNEAU COVER INSTALLATION INSTRUCTIONS Mitsubishi L200 VEHICLE DESCRIPTION: PLEASE KEEP INSTRUCTIONS IN GLOVE BOX FOR FURTHER USE LIST OF PARTS PART NAME PART NAME PART NAME Tonneau Cover Bottom Hinge U Bolt Corner Piece LHS Retainer Clip...
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Page 2: Maintenance
Disclaimer In the event that your EGR Tonneau Cover 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 labor are not associated with this warranty claim. - Page 3 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 RECOMMENDED TOOLS LIST TOOL NAME TOOL NAME TOOL NAME Phillips Head Screwdriver Spanners Caulking Gun & Silicon Rivet Gun Sockets Tape Measure Masking Tape Hammer & Centre Punch Knife Drill Pencil Allen Key Ø5mm &...
- Page 4 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 REMOVE SPORTS BAR AND RETAIN ALL HARDWARE. THOROUGHLY CLEAN AND DRY THE INSTALLATION AREA. FIG. 1 APPLY MASKING TAPE TO THE INNER BEDRAIL AS SHOWN. FIG. 2 108mm MEASURE FROM REAR OF FLANGE 18mm MEASURE AND MARK A LINE ON THE SIDE RAIL 108MM FROM THE REAR OF THE SIDE RAIL AS SHOWN.
- Page 5 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 SIDE VIEW Ø5mm CENTRE PUNCH, CENTRE PUNCH, Ø6mm THEN DRILL Ø5MM THEN DRILL Ø6MM HOLES HOLES 20mm CENTRE PUNCH THE TWO (2) FRONT HOLE POSITIONS AND DRILL Ø5MM HOLES. CENTRE PUNCH THE TWO (2) REAR HOLE POSITIONS AND DRILL Ø6MM HOLES.
- Page 6 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 MEASURE FROM TOP OF SIDE RAIL 13mm 13mm ATTACH U BOLTS ONTO LOCK STRIKERS AND LOCK STRIKER SUPPORT BRACKETS. ADJUST SO THE TOP OF THE U BOLT IS 9MM DOWN FROM THE TOP OF THE SIDE RAIL.
- Page 7 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 ALIGN HINGE WITH PREVIOUSLY MARKED POSITION MARK THREE (3) HOLE POSITIONS TRIAL FIT BOTTOM HINGES ON THE HEADER RAIL, ALIGNING THEM WITH THE PREVIOUSLY MARKED POSITIONS. FIG. 13 MARK THE THREE (3) HOLE POSITIONS OF EACH HINGE AND REMOVE THEM FROM THE VEHICLE.
- Page 8 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 PLACE RETAINER CLIPS (WITH TAG FACING LEFT) OVER FRONT OF BOTTOM HINGES. SECURE THE BOTTOM HINGES AND THE FIG. 17 RETAINER CLIPS TO THE HEADER RAIL USING POP RIVETS AS SHOWN. NOTE: SEALING LIP...
- Page 9 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 CENTRE PUNCH, Ø6mm THEN DRILL Ø6MM HOLES APPLY RUST INHIBITOR 20mm CENTRE PUNCH THE TWO (2) HOLE POSITIONS AND DRILL Ø6MM HOLES. REPEAT FOR THE OTHER SIDE OF THE VEHICLE. FIG. 21 APPLY RUST INHIBITOR TO ALL THE DRILLED HOLES.
- Page 10 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 CLEAN THE PREVIOUSLY NOTED AREAS ON TUB WITH ALCOHOL WIPE PROVIDED AND WIPE AWAY RESIDUE WITH A DRY CLEAN FIG. 25 CLOTH. POSITION CLEAR ANTI-RUB PADS AT THESE AREAS ON THE TUB. SPORTS BAR...
- Page 11 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 ENSURE CLEARANCE TO TUB LOOSEN HINGE SCREWS TO ADJUST TONNEAU RE-TORQUE 5Nm NEXT STEP POSITION IF NECESSARY IMPORTANT: THE TONNEAU COMES FITTED WITH TWO (2) RUBBER SPACERS TO ASSIST IN ALIGNMENT TO THE TUB.
- Page 12 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 ADJUST LENGTH OF ENGAGE LOCK REPLACE LOCK PLASTIC RETAINER PULLRODS BY ROTATION INSPECTION COVER CLIPS BACK IN POSITION LATCH MECHANISM “CLICK” RETAINER CLIPS ROTATE PULLRODS PRESS LATCH CLOCKWISE = SHORTEN INSPECTION TEST LOCKING MECHANISM...
- Page 13 MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194 REMOVAL OF TONNEAU COVER TO REMOVE: OPEN TONNEAU COVER AND DETACH GAS STRUTS BY INSERTING A SMALL SCREW DRIVER AND ADJUSTING THE SPRING CLIP ON THE FIG. 1 STRUT AS SHOWN. NOTE: DO NOT REMOVE THE SPRING CLIP. ONLY A SMALL AMOUNT OF LEVERING IS REQUIRED TO DETACH.