Kk-k9-f16-k Installation Instructions K9 Kit For

Transcript

KK-K9-F16-K INSTALLATION INSTRUCTIONS K9 Kit for 2011-2016 FORD EXPLORER (Retail Model Vehicle with OEM Center Shifter Console) TOOLS Needed: Phillips Screw Driver Standard Socket set Metric Socket set Power Drill with Drill Bits Wire Cutters /Crimpers Awl and 90° Scribe Trim panel removal tool Caulk Gun PARTS & HARDWARE: QTY DESCRIPTION 1 Floor 1 Rear wall 1 Passenger side lower filler 1 Driver side lower filler 1 Front wall / bulkhead with sliding door 1 Ceiling 2 Lower “B” pillar bracket 2 Upper “B” pillar bracket 1 Rear floor bracket A 1 Rear floor bracket B 1 Front floor bracket 1 Passenger side upper filler 1 Driver side upper filler 1 Rubber Mat 2 Ceiling vent / duct 1 Driver side door panel 1 Passenger side door panel 1 Driver side hinged window guard 1 Passenger side hinged window guard 1 Dome Light Kit 1 Silicone caulk (sealant) 33 1/4 x 3/4” Carriage bolt – Stainless Steel 33 1/4” serrated nut 8 1/4 x 3/4” Phillips pan head screw - Stainless Steel 8 1/4 Flat washer - Stainless Steel 3 1/4 x 3/4” Hex head bolt 3 1/4 Flat washer 10 #10 x 1/2 Phillips flat head sheet metal screws - SS 14 #10 x 1/2 Phillips pan head sheet metal screws - SS 20 #10 x 3/4 Phillips pan head sheet metal screws- SS 2 Rubber Bumper 2 6MM nut PART # KNM004351 KNM004352 KNM004353 KNM004354 KNM004440 KNM004356 KNM004369 KNM004370 KNM004375 KNM004376 KNM004393 KNM004404 KNM004405 KNM004408 KNM004392 DP-F18-1A DP-F18-6A WGI-F18-1-K9 WGI-F18-6-K9 KK-K9-DOME-LED PRM97343 GSM32024 GSM30170 GSM34102 GSM31048 GSM33001 GSM31005 GSM34150 GSM34169 GSM34170 GSM21105 GSM30201 KK-K9-F16-K_INST_6-11 rev 5-14 NOTES!  Read all instructions before installing any Havis, Inc. products.  Use hardware provided with install kit.  Vehicle battery should be disconnected during installation. It will need to be temporarily reconnected to move electric seats or check electric door locks. KK-K9-F16-K Assembly (Door panels and window guards not shown) KNM004370 Upper “B” Pillar Bracket KNM004369 Lower “B” Pillar Bracket KNM004392 Ceiling vent / duct KNM004356 Ceiling KNM004404 Passenger side upper filler KNM004405 Driver side upper filler KNM004355 Front Wall KNM004353 Passenger side lower filler KNM004352 Rear Wall KNM004375 Rear floor bracket A KNM004351 Floor KNM004354 Driver side lower filler KNM004376 Rear floor bracket B KK-K9-F16-K_INST_6-11 rev 5-14 Remove rear passenger door panels first. Behind the door open paddle handle, remove plastic cover and bolt. (10mm socket) Underneath door handle, remove plastic cover and bolt. (10mm socket) Note: A small 90° scribe helps to pick plastic covers off. Remove / unsnap entire door panel from door. (Trim removal tool) Disconnect latch cable from door handle. Remove window switch from door panel and reattach it to original plug. Neatly wire tie the speaker wire, switch wire with switch inside the speaker cavity so it does not interfere with the window operation. Carefully remove the door lock rod from O.E.M. lock assembly or loosely wire tie it out of the way. NOTE: It is very important that lock rod does not prevent the electric lock from working. Removing the rod is recommended Remove screws at bottom of door panel. (7mm socket) Remove door speaker. (7mm socket) NOTE: It is very important to check the lock operation several times before installing the new K9 door panel. To simulate the door closing, Use a tool to close the latch mechanism. Use exterior handle to open latch. KK-K9-F16-K_INST_6-11 rev 5-14 Make sure O.E.M. door parts are secure and locks and windows are operational by using front door controls. Fold seats up in order to access the seat floor mounting hardware. Middle seats have a total of four (4) bolts and four (4) nuts to remove. Remove and save hardware for K9 front floor bracket. (15mm socket) Remove third seat forward brackets. Save nuts for K9 rear floor bracket. (13mm socket) Temporarily remove plastic panels to access the third seat rear brackets. Remove seat and seat belt bolts. (13mm socket) Temporarily remove (unsnap) rear cargo hatch door sill trim panel. Temporarily remove (unsnap) rear cargo side wall trim panels. NOTE: This is necessary in order to get rear seat out. Remove seat and replace seat bolts. (13mm socket) NOTE: Be very careful not to damage the rear air conditioning refrigerant lines. Replace all cargo trim panels. Interior is now ready for K9 equipment installation. KK-K9-F16-K_INST_6-11 rev 5-14 Place K9 kit door panel onto door. The top will hook onto rubber molding. Position so it lines up with the two existing (protruding) bolts. Drill mounting holes with 5/32” drill bit. Attach door panels with #10 x 3/4 Phillips pan head sheet metal screws. Attach rubber bumper to OEM door stud with 6mm nut. This will go on top of existing nut. Bumper is used as a stud guard. This step can be done before or after the door panel installation, but make sure the stud is center on the hole. NOTE: Window guards are shipped flat. On the edge of a work bench, bend a contour in the middle of the guard so it will fit tight against the window frame. Position window guard inside window frame. Use 5/32” drill bit and drill hinge mounting holes in door panel. Attach hinge with # 10 x 1/2 Phillips pan head sheet metal screws. With upper mount bracket attached to window guard, mark mounting hole locations in upper door / window frame. Drill 5/32 holes. Attach upper mount bracket with #10 x 1/2 Phillips flat head sheet metal screws. Attach front bracket and rear floor bracket “A” with previously removed O.E.M. seat mount hardware. Tighten hardware. (13mm and 15mm sockets) Attach rear floor bracket “B” to K9 floor with 1/4 x 3/4 carriage bolts and serrated nuts. Tighten hardware. (7/16 socket) Door Panel and Window Guard complete. NOTE: It is very important to check the lock and window operation several times before closing door. KK-K9-F16-K_INST_6-11 rev 5-14 Place floor into vehicle. Loosely attach rear floor bracket “B” to rear floor bracket “A” with 1/4 x 3/4” hex head bolts and flat washers. Note: Bracket “A” already has nutserts installed. Attach front floor bracket to K9 floor with 1/4 x 3/4 carriage bolts and serrated nuts. Tighten all floor hardware. (7/16 socket) Loosely attach rear wall to floor with 1/4 x 3/4 round head Phillips bolts and washers. Note: Floor already has nutserts installed. Remove O.E.M. grab handles on “B” pillar. Reuse original hardware and loosely attach front wall mounting brackets. (7mm socket) Attach front wall to “B” pillar brackets with 1/4 x 3/4 carriage bolts and serrated nuts. (7/16 socket) Loosely attach bottom of front wall to floor with 1/4 x 3/4 Carriage bolts and serrated nuts. Loosely attach ceiling to front wall with 1/4 x 3/4 carriage bolts and serrated nuts. Loosely attach ceiling to rear wall with 1/4 x 3/4 carriage bolts and serrated nuts. . KK-K9-F16-K_INST_6-11 rev 5-14 Determine correct driver and passenger side upper and lower filler panels. Loosely attach top filler panel to ceiling and rear wall with 1/4 x 3/4 carriage bolts and serrated nuts. Note: Filler panel flange goes behind wall and underneath ceiling as shown. Loosely attach lower filler to rear wall with 1/4 x 3/4 carriage bolts and serrated nuts. Attach filler to floor with 1/4 x 3/4 round head Phillips bolts and washers. Note: Filler panel flanges go in front of wall and floor as shown. Use an Awl or other pointed tool to help align mounting holes. After all parts are attached, double check and tighten all hardware. Adjust as necessary to minimize gaps. (7/16 socket or wrench and Phillips screwdriver) Insert ceiling vent / ducts and attach with #10 x 1/2 Phillips pan sheet metal screws. Vent / ducts will line up directly below the O.E.M. ceiling vents. Insert and attach dome light to ceiling with #10 x 1/2 Phillips pan sheet metal screws. (connect wire before installing) Wire dome light to on/off switch. Switch location to be determined by the installer. K9 kits include an LED dome as of 1/3/2014 See instructions included with LED light. Neatly silicone / caulk the lower seams to shed water out of vehicle. Note: The floor pan is designed to minimize the need for sealant. Caulk (sealant) is mostly needed where the floor meets the door sill and lower filler panels. Note: Make sure the O.E.M. vents are fully open. KK-K9-F16-K_INST_6-11 rev 5-14 Example mounting location for the optional Hot-N-Pop door gas spring. Example mounting location for the optional Hot-N-Pop exhaust fan. Note: Fan can be mounted to either side of the real wall. Fan does not mount to window guard. After silicone is dry (preferably overnight), place rubber mat into K9 insert. View of completed KK-K9-F16-K installation KK-K9-F16-K_INST_6-11 rev 5-14