PARTS & HARDWARE: QTY DESCRIPTION PART

Transcription

1 KK-K9-F18-K INSTALLATION INSTRUCTIONS K9 Kit for FORD INTERCEPTOR UTILITY ** For K9 applications, it is recommended to order the Interceptor Utility with the OEM optional Aux Rear Air conditioning. (Ford option code 17A) TOOLS Needed: Phillips Screw Driver Trim panel removal tool Caulk Gun Standard Socket set Wire Cutters /Crimpers Foam cutting tool Metric Socket set T-20 Torx bit PARTS & HARDWARE: QTY DESCRIPTION PART # 1 Front bulkhead with sliding door KNM Lower B pillar bracket KNM Upper B pillar bracket KNM Rear bulkhead KNM Rear bulkhead reinforcement bracket KNM Floor KNM Front floor bracket KNM Rear floor bracket (lower) KNM Rear floor bracket (upper) KNM Ceiling KNM Ceiling air duct vents KNM Passenger side upper filler (large) KNM Passenger side upper filler (small) KNM Driver side upper filler (large) KNM Driver side upper filler (small) KNM Passenger side lower filler KNM Driver side lower filler KNM Rubber Mat KNM Driver side door panel DP-F18-1A 1 Passenger side door panel DP-F18-6A 1 Driver side hinged window guard WGI-F18-1-K9 1 Passenger side hinged window guard WGI-F18-6-K9 1 Dome Light Kit KK-K9-DOME-LED 30 1/4 serrated flange nut GSM /4 x 3/4 Hex head bolt GSM /4 Lock washer GSM /4 x 3/4 Carriage bolt SS GSM /4 x 3/4 Phillips pan head screw - SS GSM /4 Flat washer - SS GSM #10 x 1/2 Phillips flat head sheet metal screw - SS GSM #10 x 1/2 Phillips pan head sheet metal screw SS GSM #10 x 3/4 Phillips pan head sheet metal screw- SS GSM Silicone caulk (sealant) PRM Rubber Bumper GSM MM nut GSM30201

2 NOTES! Read all instructions before installing any Havis, Inc. products. Use hardware provided with install kit. KK-K9-F18-K Assembly (Door panels and window guards not shown) KNM Driver side Large upper filler KNM Upper B Pillar Bracket KNM Lower B Pillar Bracket KNM Driver side Small upper filler KNM Air Duct Vents KNM Passenger side Large upper filler KNM Passenger side Small upper filler KNM Ceiling KNM Passenger side lower filler KNM Front Bulkhead KNM Rear bulkhead reinforcement bracket KNM Rear Bulkhead KNM Front floor Not Shown KNM Floor KNM Driver side lower filler KNM Lower rear floor bracket KNM Upper rear floor bracket

3 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 screws at bottom of door panel. (7mm socket) Remove / unsnap entire door panel from door. (Trim removal tool) Disconnect latch cable from door handle. Remove door speaker. (7mm socket) Remove window switch from door panel and reattach it to original plug. Tape the switch to the vapor barrier to protect it from moisture. Carefully remove the door lock rod from O.E.M. lock assembly. NOTE: It is very important that lock rod does not prevent the electric lock from working. Removing the rod is recommended Example mounting of lock latch release solenoid for optional Hot-N-Pop # K9-A-201 kit. 1. Drill inner door skin and bolt on solenoid. 2. OEM latch cable attaches directly to solenoid. 3. You will need to keep tension on the latch cable using cable clamps. 4. Turn latch override switch to enable lock.

4 Make sure O.E.M. door parts are secure and locks and windows are operational by using front door controls. NOTE: Double check the lock operation several times before installing the new K9 door panel. 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. Note: As of 2/2014, Door window guards have obround slotted holes to minimize the possibility of fingers accidently being put into the K9 compartment. Door Panel and Window Guard complete. NOTE: It is very important to check the lock and window operation several times before closing door. Temporarily remove rear cargo tire cover, small forward cargo floor and hard foam block filler.

5 Remove rear seat bracket nuts only. (21 mm socket) Save Hardware. DO NOT remove OEM support brace hardware. Remove rear seat side bolts. (15 mm socket) Flip seats forward and remove remaining seat nuts and bolts. (15 mm socket) Save Hardware Remove seats. Use OEM nuts and bolts to attach forward K9 kit floor bracket to seat mount locations. Note: If vehicle includes the Optional OEM wire conduit, the conduit will need to be cut or removed. Use OEM nuts to attach rear / lower K9 kit bracket to rear seat mount locations. Note: Run wiring for Dome light, rear fan and other equipment prior to installing floor. Attach rear upper floor mount bracket to lower bracket with four (4) 1/4 x 3/4" hex head bolts and lock washers. (7/16 socket) Tighten all floor bracket hardware. Loosely attach floor to floor brackets with eight (8) 1/4" x 3/4" carriage bolts and serrated flange nuts. Shift floor rearward and all floor tighten hardware. (7/16 socket) Note: Run wiring for Dome light, rear fan and other equipment prior to installing floor. Prior to front bulkhead installation, remove OEM B pillar grab handles. Attach upper front bulkhead flat L bracket to B pillar with OEM grab handle screw. ( L flange faces out as shown) (7 mm socket)

6 Attach lower front bulkhead (double bend) bracket to B pillar with OEM grab handle screw. ( L flange faces in as shown) Loosely attach front bulkhead to B pillar brackets with 1/4 x 3/4 carriage bolts and serrated flange nuts. Bracket goes on inside of bulkhead flange. Loosely attach front bulkhead to floor with 1/4 x 3/4 carriage bolts and serrated flange nuts. Note: Old version had round head Phillips bolts. Remove OEM plastic side hanger brackets. (T-20 Torx) View of rear bulkhead with reinforcement bracket. Temporarily remove and save lower outside 1/4 x 3/4 carriage bolts and serrated nuts. Loosely attach rear bulkhead to floor with 1/4 x 3/4 round head Phillips bolts and flat washers. Note: Rear cross support brace goes to rear of vehicle. Front and rear bulkheads in place. Place ceiling on top of front and rear bulkheads. Loosely attach ceiling to rear bulkhead with 1/4 x 3/4 round head Phillips bolts and flat washers.

7 Loosely attach ceiling to front bulkhead with 1/4 x 3/4 round head Phillips bolts and flat washers. Loosely attach upper filler panel to ceiling 1/4 x 3/4 round head Phillips bolts and flat washers. Loosely attach upper filler panel to rear bulkhead with 1/4 x 3/4 carriage bolt and serrated nut. Note: It may be easier to attach this bolt prior to the two ceiling bolts. View of small upper filler panel. Attach small upper filler panel to large upper filler panel with 1/4 x 3/4 round head Phillips bolts and flat washers. Attach lower filler panel to floor with 1/4 x 3/4 round head Phillips bolts and flat washers. Attach to rear bulkhead with 1/4 x 3/4 carriage bolts and serrated nuts. View of passenger side lower filler panel installed. The previously removed rear hard foam block will need to be cut before reinstallation. Mark and cut 3 inches off forward end of foam block. Cutting foam is very easy with an electric steak knife. Cut with other tool as desired.

8 Reinstall foam block into original position. Mount dome light and vents 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. Install optional 10 emergency exhaust fan # KK-K9-HA-FKT-10 on rear bulk head. Reinstall OEM rear cargo floor. Note: See optional window guard fan mount part number WGI-F18-FAN-1 For alternative fan mounting. Neatly silicone / caulk the lower seams to shed water out of vehicle. Note: The floor is designed to minimize the need for sealant. Caulk (sealant) is mostly needed where the floor meets the door sill and lower filler panels.. Example mounting location for the door gas spring for the optional # KK-K9-HP-5010-X kit Hot-N-Pop Example mounting location for the optional air circulation fan # KK-K9-FAN Optional driver side window guard / fan mount shown. Part number WGI-F18-FAN-1 **Only works with optional KK-K9-HA-FKT-10 fan** Passenger side fan mount also available - # WGI-F18-FAN-6 NOTE: 12 fan not recommended for the Interceptor Utility. KK-K9-F18-K Installation Complete