canopy cp0010 installation instructions mitsubishi triton ... mn canopy fitting... · place these...

Place these instructions in vehicle’s glove box after installation is complete

Clean Canopy with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

01/10/10 of 21

Installation Time:1 Hour (Approximately)

IMPORTANT!• Read instructions carefully before installation. It is strongly recommended that installation is conducted by an authorized dealer.• 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.

RECOMMENDED TOOL LIST - (Not Supplied in Kit)

• Loctite 277 thread locking liquid (IMPORTANT)• Phillips Head Screwdriver• Large Flat Blade Screwdriver• Medium Adjustable Spanner• Side Cutters• Sockets 10, 12 & 13mm, Extension Bar and Driver• Spanners 10, 12 & 13mm• Silicon Dispensing Gun• Non Acetic Silicon (Neutral Cure)• Spray Bottle (25% isopropyl Alcohol & 75% Water)• Spray Bottle Water• Torque Wrench - 0-10Nm• Angle Grinder (Medium Size)

• Medium Paint Scraper• Non Permanent Marker• Masking Tape• Cleaning Cloths / Rags• Steel Rule and Tape Measure• Scissors (Sharp)• Knife (Sharp)• Squeegee• Metal Primer• File or Deburring Tool• (Optional) Ø5mm Drill Bit• (Optional) Rivet Gun for Stainless Steel Rivets

Mitsubishi Triton MN - Long Bed(MY09 Production Onwards)

CANOPYINSTALLATION INSTRUCTIONS

CP0010

PLEASE REFER TO PAGE 2, OF THIS INSTRUCTION FOR A LIST OF PARTS AND QUANTITIES.

This Canopy is designed to suit the (4x2 & 4x4) GLX and GL-R Triton (Double Cab).Sports Bars MUST be removed and returned to Customer with all hardware components.Cabin Guards MUST be removed and discarded.This Fitting Instruction where a Bed Liner is referred to, is based on -Mitsubishi Motors Genuine Under Rail Bed Liner Accessory only.

of 21 01/10/10

PARTS CHECK SHEET MITSUBISHI TRITON LONG BED CANOPY

CanopyQty - 1

PARTS IN MAIN CARTON

Rail ExtrusionTub Stop(ALUM0038-5)Qty - 2

Fitting Kit(KIT031895)Qty - 1

Lock Keys(Attached toCanopy InternalRear Door Handle)Qty - 2

Strona Kit -Rail Clamps(CNPY0007)Qty - 6

Clear AbrasionTape Roll48mm Wide(TAPE0611-1)Qty - 1

Tape EPDM43005.5mx20mmx9mm(TAPE0412)Qty - 1

Screw M6x30Hex Head SS304(SCRW0824)Qty - 4

M6 Flat WasherOD. 19mm(WASH0169)Qty - 8

M6 Nyloc NutSS304(NUTS0016)Qty - 4

Tape 4026 GHBWH12x1700mmx 1.14Thick Roll(TAPE0615)Qty - 1

Bulb Seal 70mmCut Length(MISC2600-1)Qty - 2

Vehicle WiringPatch Harness(LOOM0018)Qty - 1

PARTS IN FITTING KIT (KIT031895)

PARTS IN VEHICLE WIRING PATCH HARNESS KIT (LOOM0018)

Cable Ties(3) Long(2) ShortQty - 5

Adhesive TiePadQty - 1

Rivet SS304ST-ST 6-6(FAST0433)Qty - 8

40mm RubberExtrusions(MISC0521-4)Qty - 6

Scrivet(FAST0086)Qty - 1

Front Tub SpacerExtrusion(ALUM0038-6)Qty - 2

RustInhibitor

Alcohol Wipe(MISC0052)Qty - 4

AUTOMOTIVESURFACE CLEANER

IMPREGNATED WITH 70% ISOPROPYL ALCOHOL

For use in cleaning painted metal,glass and other vehicle surfaces.For external use only.Dispose of properly after use.

Rust InhibitorSatchel(MISC2776)Qty - 1

Primer Stick(MISC1365)Qty - 3

Vehicle WiringPatch Harness Kit(LOOM0018)Qty - 1

FittingInstruction(FIT-CP0010)Qty - 1

CP0010MITSUBISHI TRITON - CANOPY

FittingInstruction

01/10/10 of 21

Remove the four (4) bolts holding thesports bar feet to the tub as shown.Carefully remove the sports bar from thevehicle and return to the customer withall hardware components.(ref. diagram1).

1.

Using cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the canopy, and a piece betweenthe tub and cabin as a protection sheetwhile removing the cabin guard.(ref. diagram2).

2.

Diagram: 2 - PROTECT VEHICLE SURFACES

Apply 200mm lengths of overlappingmasking tape to the top and side of thetub rail, up to and around the cabin guardas shown.Recommended: Fit a 2mm thick steelplate as a sacrificial grinding plate (Notsupplied in kit), next to the cabin guardas shown, repeat process for the otherside of the vehicle. (ref. diagram3).

3.

Diagram: 3 - SECURE GRINDING PLATE

Diagram: 1 - REMOVE SPORTS BAR & HARDWARE


IF A SPORTS BAR IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 1.IF A CABIN GUARD IS FITTED TO THE VEHICLE, PLEASE PROCEED TO STEP 2.

IF THE VEHICLE HAS NO CABIN GUARD OR SPORTS BAR PLEASE PROCEED TO STEP 13.

13mm

FITTAPE

RECOMMENDEDFIT SACRIFICIALGRINDING PLATE

1

2

REMOVEHARDWARE

1

2

POSITIONCARDBOARD

TUB AND CABINPROTECTION MATS

CABIN GUARD

01/10/10 of 21

Secure the sacrificial grinding plate (notsupplied in kit) to the tub rail by coveringit with masking tape as shown.Repeat process for the other side of thevehicle. (ref. diagram4).

4.

Insert a suitable protective timber boardof adequate thickness between thecardboard and cabin guard as shown.IMPORTANT: To avoid accidentaldamage to the vehicle, the timber boardMUST be used when ever cutting of thecabin guard is undertaken.(ref. diagram5).

IMPORTANT: Ensure that the vehicle’s(paint work, glass, etc...) is adequatelyprotected before removing the cabinguard.Using a medium sized angle grinder,partially cut through the rear and sidefaces of the LH outer cabin guard bar,taking care not to damage vehiclesurfaces.Repeat process for the RH side of thevehicle, ensuring the protective timberboard is repositioned behind the RH outercabin guard bar. (ref. diagram6).

5.

Diagram: 5 - PROTECT VEHICLE SURFACES

6.

Diagram: 6 - REMOVAL OF CABIN GUARD

Diagram: 4 - SECURE GRINDING PLATE


PARTIALLY CUT THROUGHOUTER CABIN GUARD BARS

SECURESACRIFICIAL GRINDING

PLATE WITH TAPE

INSERTTIMBER BOARD

01/10/10 of 21

IMPORTANT: Ensure the protectivetimber board is repositioned behind each of the centre support bars beforecutting.Using a medium sized angle grinder,completely cut through the three (3)centre support bars at the base, flush tothe front tub rail, taking care not todamage vehicle surfaces. (ref. diagram7).

7.

IMPORTANT: Ensure the protectivetimber board is repositioned behind the outer cabin guard bars beforecutting.Two people are required to completethis step, one person will need tosupport the cabin guard and prevent itfrom damaging the vehicle while theother person finishes cutting throughthe cabin guard bars completely.Using a medium sized angle grinder,completely cut through the LH and RHouter cabin guard bars, flush to thegrinding plates.Carefully remove cabin guard fromvehicle and discard. (ref. diagram8).

IMPORTANT: Ensure the protectivetimber board is repositioned to each bar location before cutting.Take care to prevent damage to vehicle.Using a medium sized angle grinder,carefully cut away any remaining metalnot flush with the tub rail.Remove sacrificial grinding plates andall masking tape. (ref. diagram9).

8.


9.

Diagram: 9 - PREPARE VEHICLE SURFACES



1

2

INSERTTIMBER BOARD

COMPLETELY CUT THROUGHCENTRE SUPPORT BARS

1

2

SUPPORTCABIN GUARD

COMPLETELY CUT THROUGHOUTER CABIN GUARD BARS

1

2

GRINDAWAY ANY REMAINING

METAL NOT FLUSHWITH THE TUB

REMOVEGRINDING PLATES

& TAPE

01/10/10 of 21

Using a file / de-burring tool, remove allburrs and sharp edges from cabin guardand tub rail surfaces previously cut withthe angle grinder. (ref. diagram10).

10.

Remove all timber boards and cardboardprotection mats from the vehicle.Retain cardboard tub floor protection matfor use later during the fitment.Using compressed air, completely blowout all metal filings, swarf etc... in the tubfloor. (ref. diagram11).

Using a suitable metal primer, paint overand completely cover all bare metalsurfaces previously cut and deburred.(ref. diagram16).Allow some paint drying time by readingthrough the next steps carefully andinstalling the vehicle wiring harnessthrough the vehicle cabin.(ref. diagram12).

11.

Diagram: 11 - CLEAN VEHICLE SURFACES

12.

Diagram: 12 - PRIME VEHICLE SURFACES

Diagram: 10 - PREPARE VEHICLE SURFACES


1 REMOVETIMER BOARDS& CARDBOARD

PROTECTION MATS

DEBURRALL SURFACES AROUNDCUT CABIN GUARD BARS

2

01/10/10 of 21

Thoroughly clean and dry installationareas (tub, rear of cabin and glass)as shown.Using cardboard cut from the canopycarton, cut and place a piece inside thetub on the floor as a protection mat whileinstalling the canopy.(ref. diagram13).

13.

Open front and rear driver’s side doorsRemove and retain Front and Rear driver’s side scuff plates.Remove and retain ‘B’ Pillar trim.(ref. diagram14).

Remove and retain driver’s lower dash cover and hardware as shown.NOTE: If scrivet breaks during removal oflower dash cover, a spare scrivet has beenincluded in the hardware kit.Remove and retain driver’s side kick paneland hardware as shown.(ref. diagram15).

14.

Diagram: 14 - REMOVE VEHICLE PARTS

15.


Diagram: 13 - CLEAN & DRY INSTALLATION AREAS


POSITIONCARDBOARD TUBPROTECTION MAT

1

12

3

2

REMOVE AND RETAINFRONT SCUFF PLATE

REMOVE AND RETAIN‘B’ PILLAR TRIM

REMOVE AND RETAINREAR SCUFF PLATE

DRIVER’S SIDE OFVEHICLE ONLY

REMOVEHARDWARE

3

REMOVEHARDWARE REMOVE

KICK PANEL

4

REMOVELOWER DASH COVER

2

1

01/10/10 of 21


Unplug the brake pedal switch maleconnector from the brake pedal switchas shown.Remove and retain the bolt securing aconnector to the vehicle as shown.(ref. diagram16).

Using the vehicle wiring patch harnessfrom the hardware kit connect the femaleconnector to the brake pedal switch maleconnector as shown.Connect the male connector from the vehicle wiring patch harness back intothe brake pedal switch as shown.(ref. diagram17).

16.


17.

Diagram: 17 - CONNECT VEHICLE HARNESS

Diagram: 18 - CONNECT VEHICLE HARNESS

Route vehicle harness behind existingharness across to the kick panel and rundown to the front door scuff plates.Fit one (1) short cable tie to secure thevehicle harness to existing harness asshown. Trim excess tie with side cutters.Re-assemble the previously removedbolt and connector (from step 16) with thevehicle wiring patch harness eyelet terminaland secure to the vehicle as shownIMPORTANT: Be careful when tighteningto ensure wires are not stripped out ofthe eyelet terminal.(ref. diagram18).

18.

REMOVE AND RETAIN BOLT AND WASHER

under kick panel

2

VEHICLE WIRINGPATCH HARNESS

2

CONNECTBRAKE PEDAL HARNESS

CONNECTOR WITH VEHICLEHARNESS FEMALE CONNECTOR

1

CONNECTVEHICLE

HARNESS MALECONNECTOR

BACK INTO BRAKEPEDAL SWITCH

FEEDVEHICLE

HARNESS BEHINDEXISTING LOOMS

FITCABLE TIE

REMOVEBRAKE PEDAL

SWITCH CONNECTOR

STEERINGCOLUMN

BRAKEPEDALARM

ACCELERATORPEDAL

1

FITBOLT, EYELET

TERMINALAND CONNECTOR

21

01/10/10 of 21


Route vehicle harness from the front doorscuff plate to the rear door scuff plate,ensuring the harness sits between the‘B’ pillar sheetmetal and the seat belt asshown. (ref. diagram19).

19.

Diagram: 19 - ROUTING VEHICLE HARNESS

Lift up drivers side rear floor carpet andremove and discard the existing plug in thefloor. Feed the vehicle harness downthrough the floor and fit the vehicle harnessplug into the sheetmetal.Important: Check under the vehicle thatplug is correctly located into the sheet-metal and fully seated to prevent waterentering the vehicle.Attach one (1) long cable tie to secure thevehicle harness to the top of the chassisrail as shown. Trim excess tie with sidecutters. (ref. diagram20).

Replace driver’s side kick panel andhardware as shown.Replace driver’s lower dash cover andhardware as shown.NOTE: If scrivet broke during removal oflower dash cover, use the scrivet suppliedin the hardware kit. (ref. diagram21).

20.

Diagram: 20 - ROUTING VEHICLE HARNESS

21.

Diagram: 21 - REPLACE VEHICLE PARTS

REPLACEHARDWARE

2

REPLACEHARDWAREREPLACE

KICK PANEL

1

LIFT UPREAR FLOOR

CARPET

REPLACELOWER DASH COVER

3

4

SEAT BELT

EXISTINGHARNESS

VEHICLEHARNESS

SEAT BELT

EXISTINGHARNESS

FRO

NT

DO

OR

OP

EN

ING

RE

AR

DO

OR

OP

EN

ING

VEHICLEHARNESS

SH

EE

T M

ETA

L

SH

EE

T M

ETA

L

1

REMOVE &DISCARDEXISTING

FLOOR PLUG

2

FEEDVEHICLE HARNESS& PLUG INTO HOLEUNDERNEATH VEHICLE

3

ENSUREPLUG IS FULLY SEATED

4

FIT CABLE TIE TOHARNESS & CHASSIS RAIL

5

CH

AS

SIS

RA

IL

FRONTRAIL

SIDE RAILLHS

REAR OF TUB50mm

70mm

FRONT RAILAPPLY

DOUBLE SIDED 12x1700mm ROLL(TAPE0615) ACROSS FRONT RAIL

4

01/10/10 of 21


Replace driver’s side ‘B’ Pillar trim.Replace Front and Rear driver’s side scuffplates. (ref. diagram22).

If a bed liner is not installed proceed tostep 24.If a Bed liner is installed use a medium sizepaint scraper to separate the front rail sealfrom the tub and completely remove the seal.Re-fit the seal and fit the rail extrusion tubstop (ALUM0035-5) between the front railand seal as shown.Measure and ensure the rail extrusion tubstop is centred in the tub. (ref. diagram23).

22.

Diagram: 22 - REPLACE VEHICLE PARTS

23.

Diagram: 23 - FIT RAIL EXTRUSION TUB STOP

Diagram: 24 - FIT 3M TAPE 12x1700mm

Using alcohol wipe provided clean thehighlighted faces of the front rail and wipeaway residue with a dry clean cloth.If heavy cleaning is required use Iso-Propyl alcohol and wipe away residuewith a dry clean cloth.Apply (MISC1365) primer stick to high-lighted surfaces and allow to dry. Starting with a small amount of the tapefrom the double sided tape roll 12mm wide(TAPE0615), apply it starting from theedge of the side rail along the top face70mm then roll smoothly onto the front faceover 50mm and reverse the process for theother side of the vehicle.Apply firm pressure to ensure the tapeadheres to the vehicle.IMPORTANT: Ensure the tape sits flatand DOES NOT pucker. (ref. diagram24).

24.

32

1

REPLACEFRONT SCUFF PLATE

REPLACE‘B’ PILLAR TRIM

REPLACEREAR SCUFF PLATE

DRIVER’S SIDE OFVEHICLE ONLY

SEPARATE & REMOVEFRONT RAIL SEAL

1

RE-FITFRONT RAIL SEAL

2

BED LINER

BED LINER

RAIL EXTRUSIONTUB STOPFRONT RAIL

SEAL

FITRAIL EXTRUSION TUB STOP

3CENTRE

RAIL EXTRUSIONTUB STOP

VEHICLES WITH A BED LINER FITTEDWILL HAVE THE RAIL EXTRUSIONTUB STOP FITTED (refer step 23)

4

=

VEHICLEFRONT RAIL

=

FRONTRAIL

SID

E R

AIL

LH

S

REAR OF TUB

POSITION TAPEAGAINST SIDE RAIL

3

50mm70mm

1

2

01/10/10 of 21


NOT SUPPLIED

FRONT EXTRUSIONTUB STOP

APPLYSILICON

FRONT TUB SPACER EXTRUSION

APPLYFIRM PRESSURE TO

ADHERE SILICON AND TAPEREMOVE

TAPE LINER3

FITFRONT TUB SPACER EXTRUSION

4

12APPLY

PRIMER2

If a bed liner is not installed proceed tostep 27.If a bed liner is installed apply non-aceticsilicon (neutral cure), (not supplied) to thegap between the front tub rail and the fronttub stop extrusion across the vehicle, andthe edge of the side rail as shown.Do Not apply silicon over the side rails.Do Not allow silicon to contact thedouble sided tape.If silicon does end up on the side rail, cleanall excess silicon off using isopropyl alcohol.IMPORTANT: There must be NO siliconresidue left on the top of the side bed railfaces, or the bed rail foam tape will notadhere correctly and water leaks willoccur. (ref. diagram25).

25.

Diagram: 25 - APPLY SILICON TO THE FRONT RAIL

Using alcohol wipes provided clean thetape contact surfaces of the front tub spacerextrusion (ALUM0038-6) and wipe awayresidue with a dry clean cloth as shown.Apply (MISC1365) primer stick to tapecontact areas on extrusion and allow it to dry. Remove liner from the double sided tapeapplied to the front tub rail.Fit rail extrusion spacer to the front rail overthe tape and silicon positioning it evenlybetween the side rails and align tub spacerextrusion slots with tub stop extrusion slots.When fitting, avoid wiping the silicontowards the double sided tape.Apply firm pressure rearward and down onthe front tub spacer extrusion along thelength to ensure maximum adhesion of thesilicon and foam tape. (ref. diagram26).

If a bed liner is installed proceed tostep 29.If a bed liner is not installed, use alcoholwipes provided clean the tape contactsurfaces of the front tub spacer extrusionand wipe away residue with a dry clean cloth.Apply (MISC1365) primer stick to tapecontact areas on extrusion and allow it to dry. Remove liner from the double sided tapeapplied to the front tub rail.Fit rail extrusion spacer to the front rail overthe tape positioning it evenly between theside rails as shown.Apply firm pressure rearward and down onthe front tub spacer extrusion along thelength to ensure maximum adhesion of thefoam tape. (ref. diagram27).

26.

Diagram: 26 - FIT RAIL EXTRUSION SPACER

27.

Diagram: 27 - FIT RAIL EXTRUSION SPACER

FRONT RAIL

DOUBLESIDED TAPE

APPLYSIILICON

DOUBLESIDED TAPE

SIILICON

DO NOT APPLY SILICONOVER THE SIDE RAIL OR

OVER THE DOUBLE SIDED TAPE

FRONT TUB SPACER EXTRUSION

12APPLY

PRIMER2

5

APPLYFIRM PRESSURE TO

ADHERE TAPEREMOVE

TAPE LINER3

FITFRONT TUB SPACER EXTRUSION

4

5

DOUBLESIDED TAPE

NOT SUPPLIED

01/10/10 of 21


Apply non-acetic silicon (neutral cure),(not supplied) to the joint between the fronttub rail and the front tub spacer extrusionacross the vehicle as shown.Where the front rail drops down from thefront tub spacer extrusion as shown incentre cross section, fill the area with siliconto seal between the front rail and thefront tub spacer extrusion as shown.Do Not apply silicon over the side rails.Do Not allow silicon to contact the doublesided tape.If silicon does end up on the side rail, cleanall excess silicon off using isopropyl alcohol.IMPORTANT: There must be NO siliconresidue left on the top of the side bed railfaces, or the bed rail foam tape will notadhere correctly and water leaks willoccur. (ref. diagram28).

Using alcohol wipes provided clean alltop rail areas of the tub and wipe awayresidue with a dry clean cloth. If heavycleaning is required use Iso- Propylalcohol and wipe away residue with adry clean cloth.Ensure no silicon is squeezed up by thefitting of the front tub spacer extrusion,if it is clean it off with IPA on a ragheavily loaded. (ref. diagram29).

28.

Diagram: 28 - APPLY SILICON TO THE FRONT RAIL

29.

Diagram: 30 - MARK TUB RAILS FOR TAPE ALIGNMENT

(1) Open the rear tailgate.(2) Using non-permanent marker, measureand mark lines 5mm outboard from theinside edge of the side rails at intervals of150mm as shown.(3) Measure and mark lines 5mm rearwardfrom the front edge of the front tub spacerextrusion at intervals of 150mm as shown.(4) Mark a point on the side rails in line withthe back face of the sheetmetal flange.(5) Measure and mark a line 20mm forwardon the side rails and another line 10mmforward again.(6) Mark a point 20mm outboard on theside rails. (7) Mark a diagonal line as shown usingmarked lines and points. (ref. diagram30).

30.

Diagram: 29 - VEHICLE SURFACE PREPARATION

OPEN VEHICLETAILGATE

TOP VIEW OFVEHICLE TUB

CABIN OF VEHICLE

1

2

5

6

3

SID

E R

AIL

SIDE RAIL

SHEETMETALFLANGE

TAILGATE

FRONT TUBSPACER

EXTRUSION

5mm

5mm

10mm20mm

20mm

47

DOUBLESIDED TAPE

FRONTRAIL

FRO

NT

TUB

SPA

CE

R E

XTR

US

ION

CROSS SECTIONOUTER FRONT RAIL

APPLYSILICON

DOUBLESIDED TAPE

FRONTRAIL

FRO

NT

TUB

SPA

CE

R E

XTR

US

ION

CROSS SECTIONCENTRE FRONT RAIL

APPLYSILICON

01/10/10 of 21


Apply EPDM foam tape (TAPE0386) fromhardware kit to the bed rails and spacer.Trim end of tape at 45° (20mm x 20mm) toalign with marks on the tub rail as shown.IMPORTANT: DO NOT CUT FOAM TAPE!Starting from one side at the rear corner,position the tape end in line with themarks on the side rail, position the foamtape using marks from step 30 as a guide,run the tape 20mm along the inside edgeof the side rail then transition it over10mm, so it is 5mm outboard of theinside edge and continue this position allthe way along the side rail in onecontinuous length, position 5mmrearward along the front tub spacer usingmarks from step 30 as a guide and downthe other side rail using marks from step30 as a guide, 5mm outboard of theinside edge to the end of the side rail transitions as per the other side.IMPORTANT: As the tape bends aroundthe corners ensure the tape sits flat andDOES NOT pucker.Trim off excess at 45° (20mm x 20mm) toalign with marks on the tub rail as shown.Ensure all foam tape areas are fully adheredto the tub and spacer by applying moderatepressure down on the tape all the wayaround the tub. (ref. diagram31).Tape MUST be fully adhered to tub railsand spacer and sit flat in one continuouslength to prevent water entering thecanopy.

31.

Diagram: 31 - INSTALL WATER SEALING TAPE

APPLYEPDM FOAM TAPEAROUND BED RAIL

TOP VIEW OFVEHICLE TUB

CA

BIN

OF

VEH

ICLE

TRIM TO 45°ALIGN TO MARKS

POSITIONEPDM FOAM TAPE

OVER THE EDGE OFTHE INSIDE RADIUS

ALONG THE SIDE RAILS

POSITIONEPDM FOAM TAPE

5mm REARWARD OFTHE EDGE OF THE

FRONT TUB SPACEREXTRUSION

ALONGSIDE RAILS

ALONGSIDE RAILS

FOAM TAPE MUST NOTPUCKER AROUND CORNERS

TRIM EXCESS TO 45° AND ALIGN TO MARKS

ALONGFRONT RAIL

WITH SPACER

5mm5mm

5mm

NOT SUPPLIED

With a clean cloth wipe down all areas ofthe internal front tub corners to besiliconed as shown. Spray areas to besiliconed with water, Do Not dry.Apply non-acetic silicon (neutral cure)(not supplied) to the top of the tub andspacer around the foam tape, inside thetub at the join between the front and sidepanels of the tub and between the tub andspacer as shown.Re-spray silicon with water and pushsilicon into gaps and clean up excesssilicon. Repeat process for the other sideof the vehicle.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram32).

32.

Diagram: 32 - APPLY SILICON

BED LINER FITTEDBED LINER NOT FITTED

EPDM FOAMTAPE

FRONT TUBSPACER EXTRUSION

BED LINER

APPLYNON ACETIC

SILICON(NEUTRAL CURE)

EPDM FOAMTAPE

APPLYNON ACETIC SILICON

(NEUTRAL CURE)

FRO

NT

TUB

SPA

CE

R E

XTR

US

ION

FRONT TUB STOP

20mm10mm

5mm

SHEETMETALFLANGE

TAILGATE OFVEHICLE

NOT SUPPLIED

CLEANCANOPY FRONT

1

01/10/10 of 21


With a clean cloth wipe down all areas tobe siliconed as shown. Spray areas to besiliconed with water, Do Not dry.Apply non-acetic silicon (neutral cure)(not supplied) to the top of the tub andspacer around the foam tape and downthe front side of the tub between the tuband the cabin, and down at least the depthof the return of the front tub spacerextrusion, from the top of the tub and pushsilicon into gaps. Repeat process for theother side of the vehicle.IMPORTANT: This step must be doneproperly to ensure the vehicle tub iswater sealed. (ref. diagram33).

33.

Diagram: 33 - APPLY SILICON

Diagram: 34 - PREPARE CANOPY

Clean front of canopy including the frontwindow.Using non-permanent marker, measureand mark lines 5mm rearward from thejoint between the sheetmetal and plastictrim for each side of the vehicle as shown.(ref. diagram34).

34.

Two people are required for this step.First tape the wiring harness to the RHside window with masking tape.Position the canopy onto the vehicletub carefully. IMPORTANT: Ensure canopy is placedfully forward on the tub in one action.DO NOT slide the canopy on the EPDMfoam tape, as this can damage thefoam tape (break the water seal).Remove masking tape and feed canopyharness down between tub and cabin (righthand side of vehicle) so it is accessibleunder the vehicle on the outside of thechassis rail. (ref. diagram35).

35.

Diagram: 35 - FIT CANOPY TO TUB

DO NOT SLIDE CANOPYON EPDM FOAM TAPE

2 FITCANOPY TO

VEHICLE

1 TAPEWIRING HARNESS

TO RH SIDE WINDOW

3FEED

CANOPY HARNESSBETWEEN TUB AND

CABIN DOWN TOCHASSIS RAIL

HARNESS

2 5mmSH

EE

TME

TAL

SID

E R

AIL

PLASTICTRIM

MARK A LINE

TOP VIEW OF TUB FRONT CORNER

FRONT TUBSPACER

EPDM FOAMTAPE

VEHIC

LE CABIN

APPLYNON ACETIC

SILICON(NEUTRAL CURE)

01/10/10 of 21

Align the canopy evenly on the tub.Canopy front face should be 5mm from thejoint between the sheetmetal and plastictrim using a straight edge rising up from themarked line in step 34. as shown.Open rear tailgate to check sidewaysalignment. Using a steel rule position thecanopy so both canopy base side railsare even to the width of the vehicle tub.(ref. diagram36).

Fit six (6) 40mm rubber extrusions to thevehicle tub rails directly under the squareholes in the canopy base rails for theclamps as shown. (ref. diagram37).

36.

Diagram: 36 - ALIGN CANOPY TO TUB

37.

Diagram: 37 - FIT RUBBER EXTRUSIONS TO TUB


FIT6 RUBBER

EXTRUSIONSTO TUB RAILS

DIRECTLY UNDERCLAMP HOLES IN

BASE RAILS

EVEN BOTH SIDESAT THE END CAPS

CANOPY BASE RAIL

VIEW FROMREAR OF CAR

DISASSEMBLE2 CLAMPS

FITTOP ‘L’ CLAMP

1

2

4

FIT & SLIDEBOTTOM

‘U’ CLAMPAPPLY

LOCTITE 277 TO BOLTS,FIT BOLT & WASHERS

TORQUE TO 8Nm

5CLOSE REAR DOOR

CHECK LATCHES ENGAGE

6READJUST

LATCH STRIKERPOSITION

(IF REQUIRED)

LOCTITE277

3

9Nm

13mm

413mm

Disassemble two (2) rail clamps.Fit the clamps to the rear holes in thecanopy base rails by fitting the top L clampdown through the hole in the rail andsliding the lower U clamp along the siderail over the rubber extrusion.IMPORTANT! Apply Loctite 277(not supplied) to the bolts liberally.Secure the clamps with the bolts andwashers as shown. Tighten to Torque 8Nm. Close the rear door firmly, holding thecentre handle without slamming it too hard. NOTE: Latch has 2 stages of engagement.Ensure canopy engages with second stageof latch. If required loosen clamps andadjust the canopy position fore and aft,re-tighten to Torque 8Nm and re-checklatching. You may also need to adjust thelatch striker hoops, loosen bolts with a10mm socket adjust and tighten toTorque 8Nm. (ref. diagram38).

38.

Diagram: 38 - FIT REAR CLAMPS AND CHECK LATCHING

5mmFROM FRONT OF CANOPY TO

VERTICAL RULER

RULER VERTICAL AT LINEMARKED IN STEP 34.

0mm

1020

3040

5060

7080

90

5mm

If a bed liner is installed proceed tostep 42.(Optional): Recommended for ‘Off Road’vehicle use (with no bed liner fitted).Mark and drill eight (8) Ø5mm holes intothe front rail tub stop and tub rail usingdimension’s as shown.Rivets must secure to raised formon tub.Apply rust inhibitor to all drilled holes inthe tub sheetmetal.Secure with eight (8) stainless steel rivetsas shown. (ref. diagram41).

41.

Diagram: 41 - (OPTIONAL) SECURE FRONT TUB STOP RAIL

RAISED FORMON TUB

175 175 175 175175 3535 175

BOTTOM GROOVEON FRONT RAIL TUB STOP

Ø5mmRust

Inhibitor

(x8)1 2 3 4

LOCTITE277

DISASSEMBLE4 CLAMPS

1

FITREMAINING CLAMPS

APPLYLOCTITE 277 TO BOLTS

23

TIGHTEN2 - REAR CLAMPSTORQUE TO 9Nm

4TIGHTEN

2 - FRONT CLAMPSTORQUE TO 9Nm

5TIGHTEN

2 - MIDDLE CLAMPSTORQUE TO 9Nm

10mm

FITFRONT RAIL TUB STOP

TIGHTEN TOTORQUE 6Nm

1

3

FITBOLT AND WASHER

SECURENYLOC NUT

AND WASHER

WASHER

NYLOC NUT

BOLT

CANOPY BASERAIL AT FRONT

2

VEHICLEFRONT TUB

SHEETMETAL

6Nm

10mm

9Nm

13mm

2

13mm

01/10/10 of 21


Disassemble remaining four (4) railclamps.Fit the clamps to the remaining holes inthe canopy base rails by fitting the top Lclamp down through the hole in the railand sliding the lower U clamp along theside rail over the rubber extrusion.IMPORTANT! Apply Loctite 277(not supplied) to the bolts liberally.Secure the clamps with the bolts andwashers as shown. Tighten the rear clamps first, then the frontclamps and finally the middle clamps, allto Torque 9Nm. (ref. diagram39).

If a bed liner is not fitted, fit front rail tubstop extrusion to the under side of thecanopy front base rail.Push extrusion up against the front of thetub and secure with four (4) M6 hex headbolts, eight (8) flat washers and four (4)nyloc nuts as shown.Tighten to Torque 6Nm. If a bed liner is fitted, secure the previouslyinstalled front rail tub stop extrusion withfour (4) M6 hex head bolts, eight (8) flatwashers and four (4) nyloc nuts as shown.Tighten to Torque 6Nm. (ref. diagram40).

39.

Diagram: 39 - FIT REMAINING CLAMPS AND TIGHTEN ALL

40.

Diagram: 40 - FIT FRONT TUB STOP RAIL

01/10/10 of 21


Using a solution of 25% isopropyl alcoholand 75% water in a spray bottle (not -supplied) Thoroughly spray along the topof the tailgate.Remove liner from clear abrasion tape.Working from one end with a 5mm over-hang, place liner on the tailgate. Trim excess tape leaving a 5mm over-hang at both ends of the tailgate.When in position use a squeegee to pushout any excess water solution and bubbles.Using a sharp knife trim tape to end oftailgate.You may need to squeegee a few times.When finished the tape is virtuallyinvisible. To ensure a good finish please take carean do not rush this step.Remove masking tape. (ref. diagram43).

43.

Diagram: 43 - APPLY ABRASION TAPE

With the canopy rear door closed, applya length of masking tape to the reartailgate, level with the bottom edge ofthe canopy rear door sash, when viewedfrom the rear horizontal position as shown.This will assist in positioning the clearabrasion tape applied to the top of thetailgate in the next step. (ref. diagram42).

42.

Diagram: 42 - APPLY MASKING TAPE

CLEARABRASION

TAPE

TRIMEXCESS CLEARABRASION TAPE

3

REMOVEMASKING TAPE

CANOPY NOT SHOWN FOR CLARITY

5

SQUEEGEE OUTEXCESS SOLUTION

BUBBLES

41

25% ISOPROPYLALCOHOL

75% WATER

APPLYCLEAR

ABRASION TAPE

ALIGNBOTTOM EDGE

OF CLEAR ABRASIONTAPE WITH TOP EDGE

OF MASKING TAPE

TAILGATE

REARDOOR SASH

MASKINGTAPE

REAR WINDOW

2

BULBSEAL

BU

LB S

EA

L FI

NG

ER

UN

DE

R C

LAM

P S

EA

L&

AG

AIN

ST

CA

NO

PY

CLAMPFRAMESEAL

TAILGATE

SIDETUBRAIL

CANOPY

FIT BULB SEAL

ALCOHOLWIPE &PRIME

SHADEDAREA

1 2

3

TAILGATE

1

2

(OPTIONAL): Strongly Recommendedfor best results for rear door to tailgatewater sealing. Using alcohol wipe provided clean directlybelow the rear door clamp front seal andwipe away residue with a dry clean cloth.Using priming stick (MISC1365) prime areadirectly below the rear door clamp frontseal. Apply only a light amount both sides of tailgate in this area, and allow to dry. Apply bulb seal 70mm (MISC2600-1) totailgate. Position bulb seal so it's fingerseals against the underside of theclamp frame seal and the canopy faceas shown and position it 20mm in from theouter edge of the tailgate as shown.(ref. diagram44).

44.

Diagram: 44 - (OPTIONAL) FIT TAILGATE SEALS

APPLYMASKING TAPETO TAILGATE

1

20

CANOPY

CABIN

TUB

1FIT

ADHESIVETIE PAD

2

CHECKCANOPY LAMP

WORKS

CHECKBRAKE LIGHTS

WORK

01/10/10 of 21


Two people are required to check thecanopy brake light is operational afterdepressing the brake pedal.Then open the rear window and checkthat the internal canopy lamp is operatingcorrectly when switched to the ’ON’position only.(ref. diagram46).

46.

Diagram: 46 - CHECK BRAKE LIGHTS AND CANOPY LIGHT

Feed the canopy harness along thechassis rail.If there is excess length on the vehicleharness, loop the harness near theconnector as shown and secure it to thechassis rail with one (1) long cable tie.Connect the canopy harness connector tothe vehicle harness connector as shown.Attach one (1) long cable tie to the canopyharness near the connector, to secure it tothe chassis rail as shown.Trim excess ties with side cutters.IMPORTANT: Wiring harnesses shouldbe positioned away from the exhaustsystem side. Preferably place it on thetop side of the chassis rail.(ref. diagram45).

45.

Diagram: 45 - CONNECT VEHICLE & CANOPY HARNESSES

Using alcohol wipe provided in the kit,clean the driver’s side top corner of thetub as shown, and wipe away residuewith a dry clean cloth.Remove tape liner from adhesive tie padand position on the tub in area previouslycleaned as shown. Apply pressure toensure maximum adhesion.(ref. diagram47).

47.

Diagram: 47 - FIT ADHESIVE TIE PAD

CONNECTCANOPY HARNESS TO VEHICLE HARNESS

1

FIT TWO (2) CABLE TIES2

CHASSIS RAIL

Clean canopy including all windowsand vehicle thoroughly .Place fitting instructions in theCustomers log book, and ensurepage 20 of these instructions arediscussed with the customer and acopy is given to the customer.(ref. diagram50).

50.

Diagram: 50 - FINAL CLEANING

01/10/10 of 21


PLACE FITTING INSTRUCTIONSIN THE CUSTOMERS LOG BOOK

FITCABLE TIE

Water test canopy checking for waterleaks. (ref. diagram49).

49.

Diagram: 49 - WATER LEAK TESTING

Fit one (1) short cable tie through theadhesive tie pad previously fitted to thefront of the tub and secure the canopywiring harness as shown. Trim excess tiewith side cutters. (ref. diagram48).

48.

Diagram: 48 - SECURE CANOPY HARNESS

WARNING! - SAFETY!• Do Not use the canopy as a passenger compartment.• Do Not operate/drive vehicle with fold up windows or rear door open. They must be closed when vehicle is in motion.• Do Not store or transport volatile materials, such as solvents, chemicals or liquids as fumes may accumulate inside canopy. Do Not allow solvents, chemicals or oils to come in contact with the canopy. If this should occur clean the canopy immediately with a mild detergent and water solution.• Do not stand/sit or rest heavy objects on Canopy.• Do not fill volatile liquid containers while inside canopy such as fuel cans.• VEHICLES FITTED WITH A BED LINER: Static electricity can cause fire when fuel is pumped into ungrounded fuel containers or equipment (eg: motorcycles, chainsaws etc..). Do Not fill fuel containers or equipment within the vehicle tray as static electricity can cause fuel to ignite, resulting in damage, injury or death. To avoid electricity build-up, place fuel container or equipment on the ground before filling.

MaintenanceOnly use mild detergents or wax polish. Do Not use abrasive compounds on painted or plastic finishedcanopy surfaces.The gas struts are self lubricating and should only be cleaned with a damp cloth, when regularly cleaningthe vehicle. Premature seal failure will result if solvents or lubricants are used to clean struts.Gas struts must be orientated as installed, cylinder (wide end) to canopy and rod (narrow end) to glass.Lightly coat the door and window rubber assemblies with a silicon spray after cleaning periodically.Only locks and lock recesses are to be lubricated with Graphite Powder.Vaseline may be used on the rotary catches on the rear door.DO NOT use any other lubricants or oils. Using alternative products will VOID Warranty.Check canopy attachment clamps every 1000 Km.Clamp bolt recommended torque setting is (9 Nm or 6.64 lb/ft).If removed, bolts must have LOCTITE 277 re-applied and be re-tightened on refitting to specified values.CHECK regularly that all screws and fasteners holding windows and doors are tight.The rear tailgate protection tape must be replaced periodically to minimize paint scuffing caused by the canopy rear door opening and closing.

Warranty TermsEGR warrants that the ABS Canopy will be free from defects in material and workmanship for a period of three (3) years from the retail date ofpurchase. 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.

ExclusionsThis warranty does not cover failure due to neglect, improper installation, including any modifications to installation hardware, alterations, additionof non genuine equipment, abuse, accident, normal wear and tear, lack of maintenance, misuse, and exposure to chemicals that are not safe forplastics or hardware components. Incidental or consequential damage or loss of contents due to use, neglect, lack of maintenance, misuse of EGR Canopy is sole responsibility ofthe vehicle owner and operator. Paint wear to the vehicle bed can happen with any Canopy and is the sole responsibility of the vehicle owner.Paint damage to your vehicle is not covered under this warranty.

DisclaimerIn the event that your EGR Canopy is found to be defective under the terms of this warranty, it is at the discretion of EGR to repair or replace thedefective part. Transportation costs and labour are not associated with this warranty claim.

KEY IDENTIFICATION CODE

1234

MITSUBISHI TRITON MY09 Onwards CANOPY

Please write the key identification code in the boxes above,and retain this copy with the vehicle service history.

Replacement keys can be purchased from your local dealer.

OWNERS MANUAL SUPPLEMENTIMPORTANT: PLACE THIS PAGE IN THE CUSTOMER’S

VEHICLE SERVICE BOOK.

01/10/10 of 21


Dealer Name:

Model:

Order Date:

Required By:

Canopy Colour

Canopy Checklist - Details of rectifications required: KEY No. :

Vehicle Damage Check: Detail:

Dealer Code:

Stock No:

Order No:

Vin No:

1. Check paint on canopy

2. Cleanliness of canopy inside and outside

3. Canopy sealing to tray, tub spacer rail, tub stop rail and foam tape applied correctly

4. Seal around Front of tub, vertical corners & floor with Silicone after foam tape applied

5. Tailgate clear tape fitted

6. Position canopy on tub squarely side to side, rear door closes on second stage latch (not just first latch) both sides and lower door sash seal, seals to tailgate, adjust strikers and /or door latch pull rods via access to centre door handle by removing internal door handle cover

7. Clamps are square and tight (Torque 9Nm)

8. IMPORTANT! Loctite 277 applied to all Clamp Bolt Threads

9. Rear Door, Side Door’s and Front window operation, side windows lock with keys. Check rear door handle and locks with keys. If not locking remove interior cover on rear door handle and adjust the pull rods by winding them in/out and test the door again, replace cover.

10. Operation of Brake Light

11. Operation of interior light

12. Water Tested for leaks

13. Clean up of work area

14. Comment

Record Canopy Serial Number: Checked By:

Vehicle Type: 4x2 4x4

Vehicle received and Checked by Dealer Staff:

Fitted By:

INSTALLATION CHECKLIST

01/10/10 of 21

(located on inside LH rear pillar of canopy shell)


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