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ATTACH THE GAS STRUT BRACKETS

 (BOTH SIDES)

 TO THE SIDE RAILS USING POP RIVETS AS SHOWN.

10

5

CENTRAL POSITION OF BED

DRIVER’S SIDE

10

5

PASSENGER’S SIDE

MEASURE FROM TOP OF

SIDE RAIL

0mm

10

20

30

40

50

60

70

80

90

13mm

13mm

4

B

FIG. 12

FIG. 11

FIG. 10

FIG. 9

FIND THE CENTRE OF THE BED AND MARK THE POSITION. 

TC0194

MITSUBISHI L200 3 PIECE TONNEAU COVER

17/11/09

Page 6 of 13

A

B

A = B (CENTRAL POSITION)

FIND CENTRE AND

MARK POSITION

MEASURE AND MARK THE POSITIONS AS INDICATED ABOVE FROM THE CENTRE OF THE BED FOR THE PLACEMENT OF
THE BOTTOM HINGES. 

WARNING:- RECHECK DIMENSIONS TO ENSURE CORRECT MEASUREMENT.

382.5mm

382.5mm

CENTRAL POSITION OF BED

MARK POSITIONS ON

TOP OF HEADER RAIL

21

A

B

4

21

9

20

8

9

16

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.
TIGHTEN ENSURING THE 9MM TO THE TOP OF THE SIDE RAIL IS MAINTAINED.

Summary of Contents for TC0194

Page 1: ...t Bracket Jacking Bracket Extrusion Tape Roll M6 Large Metal Washer M6 Spring Washer 11 12 13 14 15 16 17 18 19 20 2 2 2 2 4 2 2 1 4 12 QTY NO PART NAME U Bolt Rust Inhibitor Alcohol Wipe Keys M6x40mm...

Page 2: ...tics Avoid use of abrasive type cleansers as they may dull the finish The gas struts are self lubricating and should only be cleaned occasionally with a damp cloth Premature seal failure will result i...

Page 3: ...LS LIST TOOL NAME Caulking Gun Silicon Tape Measure Knife Allen Key 10 11 12 13 NO TOOL NAME Phillips Head Screwdriver Rivet Gun Masking Tape Drill 5mm 6mm Drill Bit 1 2 3 4 5 NO TOOL NAME Spanners So...

Page 4: ...4 MITSUBISHI L200 3 PIECE TONNEAU COVER 17 11 09 Page 4 of 13 1 2 MEASURE AND MARK A LINE ON THE SIDE RAIL 108MM FROM THE REAR OF THE SIDE RAIL AS SHOWN POSITION FACE B OF LOCK STRIKER BRACKET TO SIDE...

Page 5: ...NTRE PUNCH THEN DRILL 5MM HOLES CENTRE PUNCH THEN DRILL 6MM HOLES 5mm 6mm 20mm ENSURE BRACKET IS PARALLEL WITH TOP OF SIDE RAIL ALIGN HOLES A B 7 8 9 20 10mm 5mm 1 MARK CENTRE PUNCH DRILL 5mm HOLE APP...

Page 6: ...9 Page 6 of 13 A B A B CENTRAL POSITION FIND CENTRE AND MARK POSITION MEASURE AND MARK THE POSITIONS AS INDICATED ABOVE FROM THE CENTRE OF THE BED FOR THE PLACEMENT OF THE BOTTOM HINGES WARNING RECHEC...

Page 7: ...6 FIG 15 FIG 14 FIG 13 REMOVE MASKING TAPE AND APPLY RUST INHIBITOR TO DRILLED HOLES TC0194 MITSUBISHI L200 3 PIECE TONNEAU COVER 17 11 09 Page 7 of 13 1 ALIGN HINGE WITH PREVIOUSLY MARKED POSITION MA...

Page 8: ...SITION OF THE TWO 2 HOLES AS SHOWN REPEAT FOR THE OTHER SIDE 21mm ALIGN EDGE OF JACKING BRACKET WITH EDGE OF GAS STRUT BRACKET 5 17 CLEAN HEADER RAIL AND HINGES WHERE EXTRUSION WILL SIT WITH ALCOHOL W...

Page 9: ...LE FIG 22 CENTRE PUNCH THE TWO 2 HOLE POSITIONS AND DRILL 6MM HOLES REPEAT FOR THE OTHER SIDE OF THE VEHICLE APPLY RUST INHIBITOR TO ALL THE DRILLED HOLES FIG 21 TC0194 MITSUBISHI L200 3 PIECE TONNEAU...

Page 10: ...N COVER BY REMOVING SCRIVETS AND ROTATING COVER ANTI CLOCKWISE RELEASE PLASTIC RETAINER CLIPS AND UNCLIP RODS AS SHOWN LOOSEN THE FOUR 4 LATCH MECHANISM SCREWS SO THE LATCH CAN MOVE FREELY FOR TONNEAU...

Page 11: ...THE NARROW END MOUNTS TO THE VEHICLE FIG 31 ENSURE NARROW END OF GAS STRUT MOUNTS TO VEHICLE TO REMOVE 13 13 5 2 3 17 15 14 INCORRECT INSPECT LATCH ENGAGEMENT CORRECT 2 ADJUST U BOLT USE A RULER TO EN...

Page 12: ...TI CLOCKWISE LENGTHEN ADJUST LENGTH OF PULLRODS BY ROTATION 3 RETAINER CLIPS LOCK PLASTIC RETAINER CLIPS BACK IN POSITION REPLACE INSPECTION COVER INSPECTION COVER TC0194 MITSUBISHI L200 3 PIECE TONNE...

Page 13: ...COVER 17 11 09 Page 13 of 13 REMOVAL OF TONNEAU COVER FIG 2 REMOVE HINGE PINS AND REMOVE THE TONNEAU COVER AS SHOWN FIG 1 RHS SHOWN 2 3 RHS SHOWN 1 TO REPLACE THE TONNEAU COVER Reverse the sequence an...

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