mitsubishi triton mn onwards 1 & 3 piece tonneau ... mn...mitsubishi triton 1 & 3 piece remote...

MITSUBISHI TRITON MN onwards1 & 3 PIECE TONNEAU REMOTE LOCKING KIT

INSTALLATION INSTRUCTIONS

21/03/17Page 1 of 10 TC0376

RECOMMENDED TOOLS LISTTOOL NAME

Rivet Gun

Drill

Ø5mm & Ø12mm Drill Bits

Spanners

1234

NO. TOOL NAME

Hammer & Centre Punch

Caulking Gun & Silicon

Tape Measure

Sharp Knife

5678

NO.

1 2 3 4 5 6 7 8

Ø12mmØ5mm

PLEASE KEEP INSTRUCTIONS IN GLOVE BOX FOR FURTHER USE

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

• Read Instructions carefully before installation.• It is strongly recommended that installation is conducted by an authorised 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.• Do not cycle remote key fob continuously or the actuator for operation of the remote locking system will burn out.

Maintenance:

• 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 regularly for tightness.

21/03/17Page 2 of 10 TC0376

MITSUBISHI TRITON 1 & 3 PIECE REMOTE LOCKING KIT

Double SidedFoam Tape Gasket(TAPE614)Qty - 1

5

Actuator(LOCK0004-1)Qty - 1

9

Long SelfTapping Screw(SCRW0735)Qty - 2

10

Gas Strutwith Switch(STRT0001-2)Qty - 1

11

Vehicle WiringHarnessQty - 1

1

Gas StrutEarth WireQty - 1

3

T-ConnectorLoomQty - 1

6

Male TerminalHousingQty - 1

Cable TieQty - 12

AdhesivePadQty - 3

7 17 20

Phillips HeadScrew(SCRW0648-2)Qty - 1

12

Lock Cam withBall Stud(CLIP2419-3)Qty - 1

13

Spacer(FAST0466)Qty - 1

14

Pull Rod Clip(MISC2474)Qty - 1

15

Pop Rivet(FAST0505)Qty - 1

16

Rust Inhibitor(MISC2776)Qty - 1

18

Alcohol Wipe(MISC0052)Qty - 1

19

FittingInstruction(TC0376)Qty - 1

VehicleWiring Kit(LOOM0011)Qty - 1

TonneauWiring Kit(LOOM0002B)Qty - 1

FittingInstructions

AUTOMOTIVESURFACE CLEANE

R

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.

PARTS IN MAIN CARTON - (KIT031823)

PARTS IN VEHICLE WIRING KIT - (LOOM0011)

PARTS CHECK SHEET

Tonneau WiringHarnessQty - 1

2

Interior LightQty - 1

4

ModuleQty - 1

8PARTS IN TONNEAU WIRING KIT - (LOOM0002B)

21/03/17Page 3 of 10

FIG. 4


REMOVE THE FRONT AND REAR SCUFF PLATES ON THE DRIVER’S SIDE OF THE VEHICLE ONLY.REMOVE THE DRIVER’S SIDE KICK PANEL BY FIRST REMOVING THE SCRIVET.

TC0376

FIG. 3

FIG. 2

FIG. 1REFER TO THE TONNEAU INSTALLATION INSTRUCTIONS, TO REMOVE THE TONNEAU COVER.LAY THE TONNEAU COVER UPSIDE DOWN ON A SHEET OR MAT TO PREVENT SCRATCHING.

REMOVE AND DISCARD GAS STRUT FROM THE PASSENGER SIDE OF THE VEHICLE. USING A Ø5mm DRILL BIT, DRILL OUT THE REAR RIVET ON THE GAS STRUT BRACKET AS SHOWN (PASSENGER SIDE ONLY).

RIVET THE GAS STRUT EARTH WIRE (PASSENGER SIDE ONLY) TO THE GAS STRUT BRACKET AS SHOWN.ATTACH THE GAS STRUT FROM THE KIT TO THE VEHICLE AND SECURE EARTH WIRE AS SHOWN.ENSURE THE NARROW END MOUNTS TO THE VEHICLE.

1 1

DRIVER’S SIDE ONLY

REMOVEKICK PANEL

REMOVESCRIVET

3

2

TonneauInstructions

TO REMOVE:

1

PASSENGER SIDEØ5mm

2

1 PASSENGER SIDE ONLY

PASSENGER SIDE ONLY

ENSURE NARROWEND OF GAS STRUT

MOUNTS TO VEHICLE

PASSENGER’S SIDE ONLY2

(BOTTOM)

3

113

16

REMOVEFRONT SCUFF

PLATE

REMOVEREAR SCUFF

PLATE



21/03/17Page 4 of 10 TC0376

FIG. 5REMOVE AND RETAIN THE FRONT PANEL AND HARDWARE, FROM THE REAR DRIVER’S SIDE WHEEL ARCH AS SHOWN.REMOVE RUBBER GROMMET TO GAIN ACCES TO VEHICLE CABIN.

FIG. 6MARK AND CENTREPUNCH 50mm ACROSS FROM THE BOTTOM RIGHT CORNER OF THE RHS BOTTOM HINGE AS SHOWN.DRILL A Ø12mm HOLE AND APPLY RUST INHIBITOR.

FIG. 7

FIG. 8

USING ALCOHOL WIPE PROVIDED CLEAN THREE AREAS INSIDE THE WHEEL ARCH ALONG THE VEHICLE WIRING LOOM TOATTACH THE ADHESIVE PADS (ENSURE THE LOWER PAD IS FITTED BELOW THE HEIGHT OF THE RUBBER GROMMET), AND WIPEAWAY RESIDUE WITH A DRY CLEAN CLOTH. REMOVE BACKING TAPE FROM THE THREE ADHESIVE PADS AND FIT TO AREASCLEANED AND APPLY FIRM PRESSURE FOR MAXIMUM ADHESION. USE A CABLE TIE ON EACH PAD TO SECURE THE VEHICLEWIRING LOOM.

FEED THE VEHICLE WIRING LOOM THROUGH THE Ø12MM HOLE AND DOWN BETWEEN THE TUB AND THE CABIN UNTIL YOUREACH THE RUBBER GROMMET AT THE END OF THE WIRING LOOM. PUSH THE RUBBER GROMMET INTO THE Ø12MM HOLE TOSEAL IT. FEED THE VEHICLE WIRING LOOM INTO THE HOLE LEADING INTO THE VEHICLE’S CABIN UNTIL YOU REACH THERUBBER GROMMET. PUSH THE RUBBER GROMMET INTO THE CABIN HOLE TO SEAL IT AS SHOWN.

DRIVER’S SIDE

DRIVER’S SIDE REAR WHEEL ARCH

FRONT OFVEHICLE

1

2

CENTRE PUNCH,THEN DRILL

Ø12MM HOLE

RHS ONLY

50mm

20mm

181

Ø12mm

2

RUBBERGROMMET

1

RUBBERGROMMET

1

GREY 4 WAYCONNECTOR

FIT THREEADHESIVE PADS

USING (3) CABLETIES SECURE

VEHICLE WIRINGLOOM TO

ADHESIVE PADS

LOWER PADFITTED BELOWTHE HEIGHT OF

THE RUBBERGROMMET

1

2

3

3


21/03/17Page 5 of 10 TC0376

INSERT THE 4-WAY MALE TERMINAL HOUSING PROVIDED INTO THE 4-WAY FEMALE TERMINAL HOUSING ON THE T-CONNECTOR.INSERT THE FOUR TERMINALS ON THE VEHICLE WIRING LOOM INTO THE 4-WAY MALE TERMINAL HOUSING. IMPORTANT: THE COLOUR OF THE WIRES MUST LINE UP WITH EACH OTHER THROUGH THE CONNECTORS AS SHOWN. THE TERMINALS MUST BE PUSHED INTO THE TERMINAL HOUSING UNTIL A DEFINITE CLICK IS HEARD.FIG. 12

FIG. 11

FIG. 10

FIG. 9FEED THE VEHICLE WIRING LOOM FROM THE REAR OF THE CABIN AND RUN IT ALONG THE EDGE OF THE CARPET FOLLOWINGTHE EXISTING WIRES UNTIL YOU REACH THE FRONT KICK PANEL AREA. CABLE TIE VEHICLE HARNESS TO EXISTING WIRES.

LOCATE AND DISCONNECT PLUGS AS SHOWN IN FRONT KICK PANEL AREA. ATTACH THE T-CONNECTOR WIRING LOOM LARGECONNECTORS PROVIDED TO THE PREVIOUSLY DISCONNECTED WIRING PLUGS AS SHOWN.

ATTACH THE EYELET ON THE T-CONNECTOR TO THE VEHICLE EARTH TERMINAL BY REMOVING THE BOLT, ATTACHING THEEYELET AND THEN REPLACING THE BOLT.

ORANGE WIRE ORANGE WIRE

BROWN WIRE

BLACK WIRE

RED WIRE

BROWN WIRE

BLACK WIRE

RED WIRE

6 1

7

1 2

17

x6

CARPET

VEHICLEWIRINGLOOMEXISTING

LOOM

1 2DISCONNECT PLUGS CONNECT T-CONNECTOR 6

6

1

6

17


21/03/17Page 6 of 10 TC0376

FIG. 16

FIG. 13

REMOVE THE INSPECTION COVER TO GAIN ACESS TO THE TONNEAU’S LOCKING MECHANISM. REMOVE AND DISCARD THESCREW AND WASHERS HOLDING THE LOCK CAM IN PLACE AS SHOWN. DO NOT REMOVE THE LOCK CAM. FIT THE BALL STUDLOCK CAM, PLASTIC SPACER, TO THE LOCKING MECHANISM USING THE PHILLIPS HEAD SCREW PROVIDED. TIGHTEN TO TORQUE 4Nm.IMPORTANT: ENSURE BOTH LOCK CAMS ARE ALIGNED WITH EACH-OTHER AND WITH THE LOCKING MECHANISM AS SHOWN.

LOCATE AND DISCONNECT PLUGS AS SHOWN IN FUSE BOX AREA. ATTACH THE T-CONNECTOR WIRING LOOM SMALLCONNECTORS TO THE PREVIOUSLY DISCONNECTED WIRING PLUGS AS SHOWN.

FIG. 15

FIG. 14REFIT THE DRIVER’S SIDE KICK PANEL AND SCRIVET.REFIT THE FRONT AND REAR SCUFF PLATES ON THE DRIVER’S SIDE OF THE VEHICLE ONLY.

3 3

DRIVER’S SIDE

REFITKICK PANEL

REFITSCRIVET

1

2

REFITFRONT SCUFF

PLATE

REFITREAR SCUFF

PLATE

DRIVER’S SIDE

FUSE BOX

2DISCONNECT PLUGS

FROM FUSE BOX CONNECT T-CONNECTOR1

REFIT THE PREVIOUSLY REMOVED FRONT PANEL AND HARDWARE, FROM THE REAR DRIVER’S SIDE WHEEL ARCH AS SHOWN.

DRIVER’S SIDE REAR WHEEL ARCH

FRONT OFVEHICLE

TORQUE 4Nm

ORIGINALLOCK CAM

LOCK CAM

1 2

IMPORTANT:THE CAM, SPACER& SCREW MUST BE

FITTED IN THE ORDER SHOWN

6

REMOVE SCREWAND WASHERSAND DISCARD

12

14

13


21/03/17Page 7 of 10 TC0376

FIG. 19

FIG. 18

FIG. 17

REMOVE DECAL LOCATED OVER HOLE AS SHOWN. LOCATE 4 SCRIVETS AND REMOVE. DO NOT REMOVE SCRIVETS FROMEARTH LOOM. PULL DRAW WIRE BACK THROUGH LARGE HOLE NEAR HINGES AND REMOVE SCRIVET FROM THIS END OF DRAWWIRE. ATTACH TONNEAU LOOM TO THIS END OF DRAW CABLE WITH A CABLE TIE AS SHOWN, DO NOT PULL CABLE TIE TIGHT.

PULL DRAW WIRE THROUGH THE LOCK COVER HOLE AND REMOVE SCRIVET. ONE PERSON WILL FEED THE LOOM AND THEOTHER WILL PULL THE DRAW WIRE.IMPORTANT: THIS IS TO BE DONE CAREFULLY AND SLOWLY. LEAVE THE DRAW WIRE ATTACHED TO THE TONNEAU LOOM.

1

ENSURE THE PULLROD AND PULLROD CLIP ON THE DRIVER’S SIDE OF THE LOCKING MECHANISM ARE ORIENTATEDCORRECTLY AS SHOWN. IF THEY ARE NOT ORIENTATED CORRECTLY, REMOVE THE PULLROD AND PULLROD CLIP ANDREATTACH THEM CORRECTLY. YOU MAY NEED TO REPLACE THE PULLROD CLIP WITH A NEW ONE PROVIDED.

REMOVE DECAL 3 PULL DRAW WIRE THROUGHHOLE AND REMOVE SCRIVET 4 ATTACH DRAW WIRE TO TONNEAULOOM WITH CABLE TIE SUPPLIED

EARTH LOOM

DRAW WIRE

PULL DRAW WIRE& LOOM THROUGH HERE

FEED LOOM IN HERE

2 REMOVE 4SCRIVETS

DRAWWIRE

2

DO NOT CUTCABLE TIE

2

FIG. 20USING A HOOK LOCATE THE HARNESS THROUGH THE LIGHT HOLE & PULL OUT LIGHT CONNECTOR & EARTH TERMINAL. YOU MAY NEED TO RE-PULL THE DRAW WIRE AT THE LOCK COVER TO ACCESS CONNECTORS.

2

1 2

HOOK

ENSURE THE PULLROD AND PULLRODCLIP ON THE DRIVER’S SIDE OF THE

LOCKING MECHANISM AREORIENTATED CORRECTLY

(IF REQUIRED)

PULLROD

15

17


21/03/17Page 8 of 10

FIG. 21

FIG. 23

FIG. 22

CONNECT THE 6-WAY MALE CONNECTOR ON THE TONNEAU WIRING LOOM TO THE MODULE.REMOVE THE PROTECTIVE BACKING FROM THE MODULE AND ADHERE IT TO THE INSIDE OF THE TONNEAU COVER AS SHOWN.

CONNECT THE 2-WAY CONNECTOR FROM THE TONNEAU WIRING LOOM WITH THE ACTUATOR. POSITION THE ACTUATORINSIDE THE TONNEAU COVER AND ATTACH WITH THE TWO (2) LONG SELF TAPPING SCREWS. CLIP THE PULLROD FROM THEACTUATOR ONTO THE LOCK CAM BALL STUD AS SHOWN. NOTE: ENSURE THE JOINING ELEMENT AND PULLROD CLIP AREATTACHED TO THE ACTUATOR. IF THEY ARE NOT, CLIP THEM INTO PLACE AS SHOWN. ALSO ENSURE ALL WIRING IS MOVEDOUT OF THE WAY AND CAN NOT INTERFERE WITH THE LOCKING MECHANISM.

FIG. 24 OPEN VEHICLE’S TAILGATE. FIT TONNEAU COVER AND SECURE HINGES WITH HINGE PINS AS SHOWN.

REMOVE SCRIVET AND PULL EARTH LOOM THROUGH LIGHT HOLE. CONNECT EARTH TERMINAL TO TERMINAL ON TONNEAULOOM. REMOVE TAPE LINER FROM ONE SIDE OF DOUBLE SIDED FOAM TAPE GASKET AND FIT GASKET TO THE INTERIORLIGHT AND APPLY PRESSURE TO ENSURE MAXIMUM ADHESION. CONNECT THE 2-WAY MALE CONNECTOR FROM THETONNEAU WIRING LOOM TO THE FEMALE CONNECTOR OF THE INTERIOR LIGHT. REMOVE TAPE LINER FROM DOUBLE SIDEDFOAM TAPE GASKET AND INSERT INTERIOR LIGHT INTO THE TONNEAU COVER AND APPLY PRESSURE TO ENSUREMAXIMUM ADHESION.. IMPORTANT: ENSURE ALL WIRING FOR THE INTERIOR LIGHT AND EARTH LOOM IS CONTAINED INSIDETHE TONNEAU COVER BEFORE INSTALLING THE INTERIOR LIGHT.

21 3

ENSURE JOINING ELEMENTAND PULLROD CLIP ARE

ATTACHED TO ACTUATOR

EARTH LOOMIN TONNEAU

RHS SHOWN

“CLICK”

2

1

3RHS SHOWN2

TC0376

2

5

2

4

1 5

JOININGELEMENT

PULLRODCLIP

3

POSITION ACTUATORINSIDE TONNEAU

8

2

32REMOVEPROTECTIVE

BACKING

MOUNT MODULEINSIDE TONNEAU

9

2

104

2

8

1

4

TC0376 21/03/17Page 9 of 10


FIG. 25ATTACH GAS STRUTS (PREVIOUSLY ATTACHED TO THE VEHICLE IN STEP 3) TO THE TONNEAU COVER AS SHOWN.ENSURE THE EARTH WIRE ON THE PASSENGER’S SIDE GETS CONNECTED TO THE GAS STRUT CONNECTOR AS SHOWN.

FIG. 27

FIG. 26

LOOSEN THE SCREW FOUND ON THE TERMINAL HOUSING ON THE PASSENGER’S SIDE GAS STRUT SO IT CAN MOVE FREELY.CLOSE THE TONNEAU COVER. INSPECT THE PASSENGER’S SIDE GAS STRUT AND ENSURE THE TERMINAL HOUSING HASCOME INTO CONTACT WITH THE GAS STRUT’S CYLINDER AS SHOWN. OPEN THE TONNEAU COVER AND TIGHTEN THE SCREW.

FIG. 28

GENTLYCLOSE

TONNEAULOOSENSCREW

OPENTONNEAU

COVER

1 2 43 5

ENSURE CONTACTHAS BEEN MADE

GASSTRUT

CYLINDER

TIGHTENSCREW

MANUALLY LOCK AND UNLOCK TONNEAU USING KEY. CHECK OPERATION OF CENTRAL UNLOCKING MECHANISM BY PRESSINGLOCK AND UNLOCK ON VEHICLE’S KEY. REVIEW OPERATION THROUGH INSPECTION HOLE. TEST OPERATION OF LOCKMECHANISM BY PRESSING TONNEAU’S PUSH BUTTON AFTER YOU HAVE PRESSED LOCK ON VEHICLE’S KEY, AND THEN AGAINAFTER YOU HAVE PRESSED UNLOCK ON VEHICLE’S KEY. FINALLY, REPLACE THE INSPECTION COVER.

TONNEAULOCKED

TONNEAUUNLOCKED

GASSTRUT

PASSENGER’S SIDE ONLY DRIVER’S SIDE

(TOP)

EARTH WIREFROM TONNEAU

11

CONNECT THE VEHICLE WIRING LOOM TO THE TONNEAU WIRING LOOM VIA THE 8-WAY CONNECTORS LOCATED AT THE FRONT OF THE TUB AS SHOWN.

1

2


FIG. 29

OPEN AND CLOSE TONNEAU WITH TAILGATE OPEN TO CHECK IF INTERIOR LIGHT IS FUNCTIONING CORRECTLY. ENSURE THELIGHT TURNS ON WHEN TONNEAU IS OPEN AND TURNS OFF WHEN TONNEAU IS CLOSED. IF INTERIOR LIGHT DOES NOT WORK,CHECK ADJUSTMENT OF GAS STRUT SWITCH (REFER TO FIGURE 26).

INTERIORLIGHT

TC0376 21/03/17Page 10 of 10

REMOVAL OF TONNEAU COVER

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

FIG. 1

OPEN TONNEAU COVER, DISCONNECT 4-WAY CONNECTORS AT THE FRONT OF TUB, THEN DISCONNECT BOTH SPADE TERMINALS ON THE PASSENGER’S SIDE GAS STRUT. DETACH GAS STRUTS BY INSERTING A SMALL SCREW DRIVER AND ADJUSTING THE SPRING CLIP ON THE STRUT AS SHOWN. NOTE: DO NOT REMOVE THE SPRING CLIP. ONLY A SMALL AMOUNT OF LEVERING IS REQUIRED TO DETACH.

4

5

3

1

PASSENGER’S SIDE ONLY

(BOTTOM) (TOP)

TONNEAUWIRING

HARNESS

3

11 11

2

RHS SHOWN2 3RHS SHOWN1

TO REPLACE THE TONNEAU COVER:Reverse the sequence and the procedures of the two (2) Figures above.

1

2


mitsubishi triton mn onwards 1 & 3 piece tonneau ... mn...mitsubishi triton 1 & 3 piece remote...

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