TC0194

3 PC TONNEAU COVER
INSTALLATION INSTRUCTIONS

VEHICLE DESCRIPTION: Mitsubishi L200

PLEASE KEEP INSTRUCTIONS IN GLOVE BOX FOR FURTHER USE

LIST OF PARTS
NO. PART NAME QTY NO. PART NAME QTY NO. PART NAME QTY
1 Tonneau Cover 1 11 Bottom Hinge 2 21 U Bolt 2
2 Corner Piece LHS 1 12 Retainer Clip 2 22 Rust Inhibitor 1
3 Corner Piece RHS 1 13 Gas Strut 2 23 Alcohol Wipe 3
4 Lock Striker Bracket 2 14 M8x50mm Bolt 2 24 Keys 2
5 Gas Strut Bracket 2 15 M8 Nut 4 25 M6x40mm Bolt 4
6 Hinge Pin 2 16 Lock Striker Support Bracket 2 26 Anti-Rub Pad 2
7 M6x15mm Bolt 8 17 Jacking Bracket 2
8 M6 Flat Washer 24 18 Extrusion Tape Roll 1
9 M6 Nut 16 19 M6 Large Metal Washer 4
10 Pop Rivet 12 20 M6 Spring Washer 12

1 2 3 4 5 6 7 8 9 10

A
B

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26

AUTOMOTIVE
SURF ACE CLEA
NER
For use in cleaning
glass and other painted metal,
vehicle surfaces
For external .
use only.
Dispose of properly
after use.
IMPREGNATED
WITH 70% ISOPROPYL ALCOHOL

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MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194

WARNING!
When in the closed position, Tonneau Cover must be latched and tailgate must be closed! Failure to do so could result in unexpected opening of the
Tonneau Cover from sudden wind gusts, which could cause damage to the vehicle and/or your Tonneau Cover!

Warranty Terms
EGR warrants that the ABS truck Tonneau Cover EGR will be free from defects in material and workmanship for a period of three (3) years from the retail
date of purchase. The gas struts are warranted for one (1) year from the retail date of purchase. This warranty only applies to the original purchaser and
is nontransferable. Warranty must be claimed with original sales receipt for proof of purchase.

Exclusions
This warranty does not cover failure due to neglect, improper installation including any modifications to installation hardware, operating the vehicle with
your EGR Tonneau Cover in the open position, alterations, addition of equipment, abuse, accident, corrosion, normal wear and tear, lack of maintenance,
and exposure to chemicals that are not safe for plastics.
Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Tonneau Cover is sole responsibility of
the truck owner and operator. Paint wear to the truck bed can happen with any truck Tonneau Cover and is the sole responsibility of the truck owner.
Paint damage to your truck is not covered under this warranty.

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.

MAINTENANCE:
Your EGR Tonneau Cover only requires periodic cleaning with mild car wash soap. Only use cleaners, waxes, or products that are labelled safe for use
on plastics. Avoid the use of any chemicals to clean your EGR Tonneau Cover unless labelled safe for plastics. 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 if solvents or lubricants
are used to clean struts.

The locking mechanisms & Latches only require occasional lubrication with Graphite Powder. DO NOT use any other lubricants or oils.
Using alternative products will VOID Warranty.

All installation hardware and fasteners must be checked every so often for tightness.

TONNEAU COVER - IMPORTANT:

• Read instructions carefully before installation. It is strongly recommended that installation is conducted by an authorized dealer.
• Do not stand/sit or rest heavy objects on Tonneau Cover.
• Humans or animals are not to be under the closed Tonneau Cover at any time.
• Securely latch Tonneau Cover before operating vehicle.
• Do not carry open volatile chemicals with Tonneau Cover installed.
• If contact with volatile chemicals occurs clean Tonneau Cover with mild detergent and water solution.
• This product must be installed exactly as specified in these instructions. Failure to do so may result in improper fit and/or retention.
• Recommend installation by 2 people.
• Approximate fitting time is 1 ½ hours.

PAINTING INSTRUCTIONS: (IF UNPAINTED)

• Prior to painting, clean all surfaces to be painted using clean water and a mild detergent, do not use lacquer thinner or any solvent based products.
Wipe completely dry.
• Best results will be achieved by wiping the areas to be painted with a tack rag just prior to painting.
• Select a top coat and clear paint that is suitable for ABS (Acrylonitrile-Butadiene-Styrene).
• Automotive paint systems, such as Acrylics or Two Packs, can be applied directly to the components. However, some paints may require a primer.
If recommendations on paint specification are not followed, cracking of the part or degradation to the material may result. In all paint systems,
aromatic hydrocarbons and alkalies are best avoided to reduce damage to the material properties.
• If using a paint system which requires baking, do not expose the product to temperatures above 70° C (155° F).
• Allow a minimum of 8 hours after baking before installation on the vehicle.

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MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194
RECOMMENDED TOOLS LIST
NO. TOOL NAME NO. TOOL NAME NO. TOOL NAME
1 Phillips Head Screwdriver 6 Spanners 10 Caulking Gun & Silicon
2 Rivet Gun 7 Sockets 11 Tape Measure
3 Masking Tape 8 Hammer & Centre Punch 12 Knife
4 Drill 9 Pencil 13 Allen Key
5 Ø5mm & Ø6mm Drill Bit

1 2 3

4 5 6

Ø5mm
Ø6mm

7 8 9

10 11 12 13

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FIG. 1 REMOVE SPORTS BAR AND RETAIN ALL HARDWARE. THOROUGHLY CLEAN AND DRY THE INSTALLATION AREA.

FIG. 2 APPLY MASKING TAPE TO THE INNER BEDRAIL AS SHOWN.

108mm
4

MEASURE FROM REAR

OF FLANGE
18mm
B
A

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 OF SIDE RAIL 18MM DOWN FROM TOP OF SIDE RAIL. ALIGN NOTCH TO PREVIOUSLY
FIG. 3 MARKED CENTRELINE. MARK THE POSITION OF THE TWO (2) LARGER HOLES AS SHOWN. REPEAT FOR THE OTHER SIDE.

MEASURE FROM
FRONT OF RAIL
37mm
772mm

28mm

FIG. 4 MEASURE FROM THE FRONT OF RAIL AND MARK THE DISTANCES AS SHOWN. REPEAT FOR THE OTHER SIDE.

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SIDE VIEW
Ø5mm
Ø6mm CENTRE PUNCH, CENTRE PUNCH,
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
FIG. 5 HOLE POSITIONS AND DRILL Ø6MM HOLES. REPEAT FOR THE OTHER SIDE OF THE VEHICLE.

22 1 REMOVE MASKING TAPE

2 APPLY RUST INHIBITOR

FIG. 6 REMOVE THE MASKING TAPE FROM THE INSIDE OF THE SIDE RAILS ONLY. APPLY RUST INHIBITOR TO ALL THE DRILLED HOLES.

20 9 ENSURE BRACKET IS
8 PARALLEL WITH
TOP OF SIDE RAIL

FIG. 7 ATTACH LOCK STRIKER BRACKETS, ENSURING BRACKETS ARE PARALLEL WITH TOP OF SIDE RAIL. TIGHTEN TO TORQUE 12Nm.

1 ALIGN HOLES
Ø5mm

16
10mm 16

2 MARK, CENTRE PUNCH,

22 3
DRILL Ø5mm HOLE
APPLY RUST INHIBITOR
10

POSITION LOCK STRIKER SUPPORT BRACKET UNDER THE LOCK STRIKER BRACKET AND ALIGN THE HOLES CLOSEST TO THE
FRONT OF THE VEHICLE AS SHOWN. MARK AND CENTRE PUNCH HOLE POSITION IN THE SIDE OF THE TUB. DRILL Ø5mm HOLE
FIG. 8 AND APPLY RUST INHIBITOR. ATTACH LOCK STRIKER SUPPORT BRACKET TO THE TUB WITH A RIVET.

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0mm
10
20
30
40
50
60
70
80
90

4
MEASURE FROM TOP OF
21 SIDE RAIL
B
13mm 13mm
9 A
4

20 B
21
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.
FIG. 9 TIGHTEN ENSURING THE 9MM TO THE TOP OF THE SIDE RAIL IS MAINTAINED.

CENTRAL POSITION OF BED

PASSENGER’S SIDE DRIVER’S SIDE

5
10 10

FIG. 10 ATTACH THE GAS STRUT BRACKETS (BOTH SIDES) TO THE SIDE RAILS USING POP RIVETS AS SHOWN.

A = B (CENTRAL POSITION)

A B

FIND CENTRE AND

MARK POSITION

FIG. 11 FIND THE CENTRE OF THE BED AND MARK THE POSITION.

CENTRAL POSITION OF BED

382.5mm 382.5mm

MARK POSITIONS ON
TOP OF HEADER RAIL

MEASURE AND MARK THE POSITIONS AS INDICATED ABOVE FROM THE CENTRE OF THE BED FOR THE PLACEMENT OF
FIG. 12 THE BOTTOM HINGES. WARNING:- RECHECK DIMENSIONS TO ENSURE CORRECT MEASUREMENT.

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1 2

11
ALIGN HINGE
WITH PREVIOUSLY
MARKED POSITION

11

MARK THREE (3)

HOLE POSITIONS
x2
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.

Ø5mm

20mm

CENTRE PUNCH,
THEN DRILL Ø5MM
HOLES (x6)

FIG. 14 CENTRE PUNCH AND DRILL Ø5MM HOLES AT THE PREVIOUSLY MARKED POSITIONS.

22
1 REMOVE
MASKING
TAPE

2 APPLY RUST
INHIBITOR

FIG. 15 REMOVE MASKING TAPE AND APPLY RUST INHIBITOR TO DRILLED HOLES.

1 2
11
11
NOT SUPPLIED

11

APPLY SILICON TO THE UNDERSIDE OF THE BOTTOM HINGES AND POSITION THEM ON THE HEADER RAIL.
FIG. 16

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10

11
12

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

MUST FACE TAILGATE 18
11 11
23
START EXTRUSION
AT EDGE OF SIDE RAIL
18
HEADER 12
POSITION EXTRUSION RAIL
AS CLOSE TO REAR RADIUS
RE
AR
OF
VEH
REAR ICL
E
18 12
CLEAN HEADER RAIL AND HINGES (WHERE EXTRUSION WILL SIT) WITH ALCOHOL WIPES PROVIDED AND WIPE AWAY RESIDUE
WITH A DRY CLEAN CLOTH. PLACE THE EXTRUSION TAPE SEAL ALONG THE TOP OF THE HEADER RAIL WITH THE SEALING LIP
FACING TOWARDS THE TAILGATE. START THE EXTRUSION AT THE EDGE OF THE SIDE RAIL. IMPORTANT: POSITION
FIG. 18 EXTRUSION AS CLOSE TO THE HEADER RAIL REAR RADIUS. RUB DOWN FIRMLY TO ENSURE MAXIMUM ADHESION.

2/3 25

19
2/3
19

25

PLACE THE CORNER PIECES OVER THE ENDS OF THE SPORTS BAR LEGS.
FIG. 19 LOOSELY ATTACH THEM TO THE SPORTS BAR. DO NOT TIGHTEN FULLY AT THIS STAGE.

ALIGN EDGE OF JACKING BRACKET

WITH EDGE OF GAS STRUT BRACKET

21mm
5

17

ALIGN EDGE OF JACKING BRACKET TO EDGE OF GAS STRUT BRACKET ON SIDE RAIL AS SHOWN, 21MM DOWN FROM TOP OF
FIG. 20 SIDE RAIL. MARK THE POSITION OF THE TWO (2) HOLES AS SHOWN. REPEAT FOR THE OTHER SIDE.

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1 CENTRE PUNCH,
Ø6mm THEN DRILL Ø6MM
HOLES

2 APPLY RUST
INHIBITOR

20mm

22

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.

1 20
8 9
NO POWER TOOLS 14 17
7
15
17
SIDE VIEW

LOOSELY PRE-ASSEMBLE ONE (1) M8x50MM BOLT AND TWO (2) M8 HEX NUTS TO THE JACKING BRACKET AS SHOWN.
ATTACH JACKING BRACKET TO THE VEHICLE, ENSURING BRACKET IS PARALLEL WITH TOP OF SIDE RAIL.
FIG. 22 TIGHTEN TO TORQUE 12Nm. REPEAT FOR THE OTHER SIDE OF THE VEHICLE.

SPORTS BAR

2
SIDE VIEW

NO POWER TOOLS

SPORTS BAR HARDWARE

POSITION THE SPORTS BAR AND CORNER PIECES ON THE VEHICLE. ATTACH THE LEGS OF THE SPORTS BAR USING THE
FIG. 23 RETAINED HARDWARE. NOTE: PUSH DOWN ON THE SPORTS BAR AND LIGHTLY TIGHTEN HARDWARE.

MARK THESE 2 EDGES

ON THE TUB
NOTE THE AREA WHERE CORNER PIECE CONTACTS THE VEHICLE TUB AS SHOWN.
MARK THE EDGES AS SHOWN WITH A PENCIL OR NON-PERMANENT MARKER. REPEAT PROCESS FOR THE OTHER SIDE.
FIG. 24 REMOVE SPORTSBAR AND CORNER PIECES FROM TUB.

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26

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

2
SIDE VIEW

NO POWER TOOLS

SPORTS BAR HARDWARE

RE-POSITION THE SPORTS BAR AND CORNER PIECES ON THE VEHICLE. ATTACH THE LEGS OF THE SPORTS BAR USING THE
FIG. 26 RETAINED HARDWARE. NOTE: PUSH DOWN ON THE SPORTS BAR BEFORE TIGHTENING HARDWARE.

2 2 RHS SHOWN 3 RHS SHOWN

1

6 6
RUBBER
SPACER’S

1
12 12
“CLICK”
OPEN TAILGATE. FIT THE TONNEAU COVER TO THE VEHICLE. SECURE THE HINGES USING THE HINGE PINS AS SHOWN.
IMPORTANT: ENSURE TAILGATE REMAINS OPEN. DO NOT REMOVE THE TWO (2) RUBBER SPACERS FROM THE TONNEAU
FIG. 27 SIDES (AT THE REAR), THESE WILL BE REQUIRED FOR ALIGNMENT LATER ON.

1 REMOVE 2 RELEASE PLASTIC 3 UNCLIP RODS FROM 4 LOOSEN SCREWS

INSPECTION RETAINER CLIPS PLASTIC RETAINER
COVER CLIPS

SCREWS
INSPECTION PLASTIC RETAINER RODS
COVER CLIPS

REMOVE INSPECTION 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
FIG. 28 FOR TONNEAU ADJUSTMENT IN THE NEXT STEP.

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MITSUBISHI L200 3 PIECE TONNEAU COVER TC0194

1 2 2

ENSURE RUBBER SPACER

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.
CLOSE TONNEAU COVER AND CHECK THAT IT IS CENTRAL ON BED. LOOSEN HINGE SCREWS - DO NOT ADJUST HINGES WHILE
GAS STRUTS ARE CONNECTED. CHECK LH & RH LATCHES ARE ENGAGED. MOVE TONNEAU TO ENSURE EVEN CLEARANCE LHS
TO RHS BETWEEN TUB AND SPACERS. MOVE TONNEAU TO ENSURE FORE & AFT POSITION IS CORRECT BY ENSURING CLEAR-
ANCE AT REAR OF TUB SIDE. RE-TIGHTEN (12) HINGE SCREWS WHILE TONNEAU IS IN CORRECT POSITION TO TORQUE 5Nm.
RE-TIGHTEN LATCHES WHILE TONNEAU IS IN CORRECT POSITION TO TORQUE 4Nm. IMPORTANT: ENSURE TAILGATE REMAINS
FIG. 29 OPEN AND SPACERS ARE REMOVED AFTER ALIGNMENT IS COMPLETE.

14 17 2/3
2/3 1
NO POWER TOOLS

15

CHECK THAT THE SURFACES OF THE TONNEAU COVER AND CORNER PIECES ARE EVEN. ADJUST THE JACKING BOLTS
UNDERNEATH THE CORNER PIECES IF NECESSARY. ENSURE CLEARANCE BETWEEN CORNER PIECE AND TUB, ESPECIALLY
FRONT AND REAR, TO AVOID PAINT DAMAGE TO TUB. ONCE IN THE CORRECT POSITION, LOCK THE M8 NUTS INTO
POSITION AGAINST THE BRACKET USING A SPANNER. REPEAT FOR THE OTHER SIDE OF THE VEHICLE.
FIG. 30 IMPORTANT: TIGHTEN ALL CORNER PIECE M6 BOLTS TO 4Nm.

TO REMOVE:

13

13
5
ENSURE NARROW
END OF GAS STRUT
MOUNTS TO VEHICLE

FIG. 31 ATTACH GAS STRUTS. ENSURE THE NARROW END MOUNTS TO THE VEHICLE.

2 INSPECT LATCH 3 ADJUST U-BOLT

ENGAGEMENT
USE A RULER TO ENSURE
U-BOLT REMAINS PARALLEL
TO LOCK STRIKER
INCORRECT
90

TORQUE 10Nm
80
70

1
60

21
50
40
30
20

CORRECT
10
0mm

4
CLOSE TONNEAU AND INSPECT LOCKING MECHANISM. ENSURE LATCH HITS THE U BOLT CENTRALLY. IF IT DOES NOT, ADJUST THE U BOLT
ACCORDINGLY BY LOOSENING THE M6 NUTS AND MOVING THE U BOLT UP OR DOWN AS SHOWN. ONCE ADJUSTMENT IS COMPLETE, TIGHTEN
FIG. 32 THE M6 NUTS. IMPORTANT: TONNEAU HAS 2 STAGE LOCKS. ENSURE TONNEAU ENGAGES WITH SECOND STAGE OF THE LATCH.

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2 ENGAGE LOCK 3 ADJUST LENGTH OF 4 LOCK PLASTIC RETAINER 6 REPLACE

PULLRODS BY ROTATION CLIPS BACK IN POSITION INSPECTION COVER
LATCH MECHANISM

“CLICK”
ROTATE PULLRODS RETAINER CLIPS
PRESS LATCH CLOCKWISE = SHORTEN INSPECTION
UPWARDS ANTI-CLOCKWISE = LENGTHEN 5 TEST LOCKING MECHANISM COVER

OPEN TONNEAU AND ENGAGE LOCK BY PRESSING UPWARDS ON LATCH. ADJUST PULLRODS TO FIT INTO RETAINER CLIPS BY ROTATING THEM
CLOCKWISE TO SHORTEN OR ANTI-CLOCKWISE TO LENGTHEN. CLIP PULLRODS AND RETAINER CLIPS BACK INTO POSITION. TEST LOCK BY
PRESSING THE BUTTON ON TOP OF TONNEAU COVER. IF LATCH MECHANISM DOES NOT RELEASE, RETURN TO STEP 3 AND SHORTEN THE
PULLRODS. FINALLY, RE-CONFIRM THE OPEN-CLOSE-OPEN OPERATION OF TONNEAU WITH THE TAILGATE CLOSED. MAKE FURTHER ADJUSTMENTS
FIG. 33 IF NECESSARY BY RETURNING TO FIGURE 29, 33 AND 34. FINALLY REPLACE INSPECTION COVER

1 2 2

LOOSEN HINGE SCREWS

TO ADJUST TONNEAU
POSITION IF NECESSARY
NEXT STEP RE-TORQUE 5Nm
CLOSE TAILGATE AND TONNEAU COVER AND RE-CHECK CLEARANCES.
LOOSEN HINGE SCREWS AND ADJUST TONNEAU FORE & AFT IF REQUIRED.
FIG. 34 DO NOT ADJUST HINGES WHILE GAS STRUTS ARE CONNECTED. RE-TIGHTEN HINGE SCREWS TO TORQUE 5Nm.

2 ADJUST U-BOLT
USE A RULER TO ENSURE
1 U-BOLT REMAINS PARALLEL
TO LOCK STRIKER
90

TORQUE 10Nm
80
70
60

21
50
40
30
20
10
0mm

CLOSE TONNEAU AND CHECK CLOSING EFFORT WITH TAILGATE CLOSED. IF REQUIRED, ADJUST THE U BOLT ACCORDINGLY BY LOOSENING
FIG. 35 THE M6 NUTS AND MOVING THE U BOLT UP OR DOWN. ONCE ADJUSTMENT IS COMPLETE, TIGHTEN THE M6 NUTS.

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REMOVAL OF TONNEAU COVER

TO REMOVE:

11

11
3

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.

1 RHS SHOWN 2 RHS SHOWN 3

6 6

12 12

FIG. 2 REMOVE HINGE PINS AND REMOVE THE TONNEAU COVER AS SHOWN.

TO REPLACE THE TONNEAU COVER:

Reverse the sequence and the procedures of the two (2) Figures above.

MITSUBISHI L200 3 PIECE HARD TONNEAU COVER

KEY IDENTIFICATION CODE

X
XX
XX

Please write your key identification code in the boxes above and retain.
Replacement keys can be purchased from your local Mitsubishi dealer.

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