MITSUBISHI FUSO FE / FG HEATED MIRROR INSTALLATION MODEL YEARS: 2001 AND UP

Transcription

1 MITSUBISHI FUSO FE / FG HEATED MIRROR INSTALLATION MODEL YEARS: 2001 AND UP NOTE: RAISE WINDOWS TO UPPERMOST POSITION. DISCONNECT NEGATIVE BATTERY LEADS PRIOR TO ALL OPERATIONS; RECONNECT ONLY WHEN INDICATED BELOW. KIT KT PARTS LIST Part Number Description QTY KT heated mirror SUBKIT* 1 MC relay, tabbed 1 MH x 12 mm flanged bolt 1 MS mm flanged nut 1 MZ these installation instructions 1 *SUBKIT KT PARTS LIST FP " x 6" cable tie, black 25 FP heated mirror head, black 2 FP /4" ID x 3/8" groove diameter rubber grommet 4 FP /8" ID x 1/2" groove diameter rubber grommet 2 FP gauge Solid Seal butt connector 4 FP /4" ID x 1/2" groove diameter split bushing 2 MB mounting tape 2 MK switch 1 MS fuse, 10A 2 DRIVER SIDE A. DOOR TRIM PANEL REMOVAL (save all parts for reuse) REMOVE: 1. Screw cover and Phillips screw at door lock handle, then door lock trim piece. 2. Phillips screw and arm rest handle pocket. 3. Trim cover near ashtray. 4. Phillips screw and latch handle pocket. 5. Three bolts (12mm head) and window arm rest. 6. Door trim panel by pulling at perimeter clips along rear, bottom, and front of door. Press down and pull outward to release tab at upper front corner then lift trim panel to release weatherstrip edge. Release window/door lock switch harness. Set trim panel and weatherstrip aside. 7. Two bolts (12mm head) and window arm rest rear bracket. 8. Two Phillips screws and arm rest brace. 9. Four Phillips screws and speaker. Disconnect speaker harness. 10. Waterproof film; set aside with adhesive side up. B. MIRROR HEAD AND MIRROR STAY REMOVAL REMOVE: MZ WLG 7/2001 PAGE 1 of 8

2 1. Upper and lower stem nuts (1/2" size) and washers from original mirror head. Loosen bolt (12mm head) at lower mirror head clamp bracket and slide bracket down to clear lower stem bolt. MZ WLG 7/2001 PAGE 2 of 8

3 2. Original mirror head from stay and set aside. Loosen (do not yet remove) acorn nut (14mm size) at top of stay. 3. Three Phillips-head bolts and plastic retainer washers (behind gasket) at lower stay bracket. 4. Acorn nut, lockwasher, steel washer, and plastic washer at top of stay. 5. Mirror stay and place on a non-marring work surface. C. WIRING PREPARATION 1. Locate the two-wire harness connector which is secured to the inner door skin with brown mounting tape figure Peel back (do not discard) brown tape to release harness. Remove black tape from harness connector figure Remove two-wire connector by cutting green and black wires flush to connector end. Strip 3/8" (10mm) of insulation from these wires. 4. Confirm that window is fully raised. Using supplied door skin/gasket template, mark door skin with center punch. (Drilled hole will be centered at 1.5" (38mm) on a line that connects the centers of the upper rear and lower mounting bolt holes.) Carefully drill 1/8" (3mm) pilot hole through the door skin and the reinforcing plate behind. Enlarge holes in skin and plate to 1/2" (13mm) figure 3 and deburr BOTH skin and plate holes figure Punch 1/2" (13mm) diameter hole in bracket gasket with gasket punch (use template from previous step to locate hole). 6. Install rubber grommet in door skin hole. 7. Mark vertical rear face of lower stay bracket with center punch at a point 2.5" from the upper bracket edge and 1/2" from the inner ridge figure 5. Carefully drill 1/8" (3mm) pilot hole. Enlarge hole with 3/8" (10mm) bit, deburr, and install rubber grommet. D. HEATED MIRROR HEAD INSTALLATION 1. Insert upper stem of FP heated mirror head (cord at bottom) into upper clamp bracket and secure with washer and 1/2 nut. 2. Slide lower clamp bracket over lower mirror stem bolt; do not yet fully tighten clamp bolt. 3. Install convex mirror (if used) on lower mirror stem bolt (below clamp bracket) and secure with washer and 1/2 nut. 4. Route jacketed mirror wires along mirror stay to lower stay bracket. 5. Loosely secure jacketed wires with cable ties (six total) starting directly above the lower clamp bracket and at each bend in the mirror stay. 6. Leaving enough slack for adjustment of the mirror stay at its forward-most rotated position, route jacketed wires through the grommet in the lower stay bracket. Ensure that the grommet remains in place; use silicone lubricant as needed. 7. Replace gasket on the lower stay bracket by routing wire through newly punched hole (hole toward rear). Insert three Phillips-head bolts and secure gasket with three plastic retainer washers figure 6. E. HEATED MIRROR / MIRROR STAY ASSEMBLY INSTALLATION 1. Install upper stem of mirror stay, Loosely secure with acorn nut (14mm size), lockwasher, steel washer, and plastic washer. PAGE 3 of 8

4 2. Feed jacketed mirror wires through grommet in door skin. Pull lightly from inside door to remove slack. Ensure that the grommet remains in place; use silicone lubricant as needed figure Install nylon split bushing by sliding over jacketed wire from interior side of door. Secure bushing in reinforcing plate hole figure IMPORTANT: IN ORDER TO PREVENT FOULING WITH THE WINDOW AND LIFT MECHANISM, THE JACKETED MIRROR WIRES MUST PRECISELY FOLLOW THE DESCRIBED PATH WITHOUT ADDITIONAL SLACK. a. Route jacketed wires FLAT against reinforcing plate vertically downward to retainer tabs at bottom of plate. b. Route wires horizontally across retainer tabs, then bend tabs upward to secure. c. Carefully apply MB mounting tape across the vertical portion of the jacketed wires to stabilize and secure them away from the window glass figure 9. d. Route jacketed wires behind window track down to existing wire harness. e. Loosely securing with cable ties, route wires along harness, below window track mounting bracket figure 10, and through the door cutout nearest the ends of the existing green and black wires. 5. Trim jacketed mirror wires leaving six-inch lead. Remove two inches of gray wire jacket, strip 3/8" of insulation from black and white mirror wires, and slide crimpless heat-shrink solder connectors over each wire. 6. Connect black-to-black, white-to-green by meshing wires ends as shown. Carefully position butt connectors with solder ring over meshed wire ends. Heat each connector with heat gun until tubing shrinks and solder melts thoroughly figure 11. Allow to completely cool before proceeding. 7. Attach completed splices to existing harness by fully wrapping with tape. 8. Loosely secure bolts in lower mounting bracket of heated mirror assembly. 9. Ensure sufficient wire slack at bracket pivot for full forward and rearward mirror travel. Fully tighten cable ties on mirror stay figure 12. Clip excess cable tie material. Trim or file tie ends flush to remove sharp edges figure Fully tighten and trim remaining cable ties. Return existing wire harness to original location and reapply brown mounting tape. Temporarily reconnect battery and confirm smooth operation of window through entire range of travel. Disconnect negative battery leads. 11. Fully tighten lower mounting bracket bolts. 12. Tighten acorn nut at top of mirror stay to 20 lb-ft. 13. Rotate mirror stay until index marks are aligned. Adjust mirror heads for proper visibility and fully tighten lower clamp bracket bolt. REPEAT STEPS A-E ABOVE FOR PASSENGER SIDE F. FINAL WIRING / RELAY AND SWITCH INSTALLATION 1. Release and lower passenger side lower dash panel. 2. Open lid and remove right-most glove box (four Phillips screws). 3. Without disconnecting harnesses, remove ABS ECU (two Phillips screws) figure While supporting ABS ECU to prevent tension on harnesses, remove Timing Control Module figure 15 as follows: Remove Phillips screw in front right corner and release module by carefully pulling back gray retainer tabs at front and rear; release wire harness connector at bottom side of module and set module aside. PAGE 4 of 8

5 5. Locate four-pin relay connector with four wires which is tagged "HEATER MIRROR" and is wrapped in blue identification tape figure Install MC tabbed relay figure 17 with MH flanged bolt and MS flanged nut in the vertical dashboard brace in the existing hole figure 18 above the existing tabbed relay. 7. Remove identification tape and attach relay connector to MC tabbed relay. 8. Re-connect harness to Timing Control Module and return module to its original location; secure module with tabs and Phillips screw. 9. Replace ABS ECU ensuring that harnesses return to open area under vent conduit. Do not disturb vent conduit or two screw clips at the front edge of the glove box opening. Secure with two Phillips screws. Replace glove box and secure with screws. 10. Locate seven-pin switch connector with four wires below the instrument cluster. The switch is tagged "HEATER MIRROR" and is secured with blue identification tape to the large harness which runs vertically downward from behind the dashboard figure Remove tape and route switch connector through dashboard bezel at the switch opening which was revealed above figure Connect MK switch and secure in switch opening with orientation as shown figure Return passenger side lower dash panel to upright position. 14. Install two MS amp fuses in the F17 (load) and F30 (relay) fuse locations. Replace fuse box cover. 15. Reconnect negative battery leads and confirm switch and mirror operation: Turn engine start key to ON position, depress ON side of mirror switch; switch L.E.D. should illuminate immediately and mirror glass will be warm to the touch within two minutes. Return start key to OFF, confirm that L.E.D. is extinguished. Depress OFF side of mirror switch. G. DOOR TRIM PANEL INSTALLATION Reverse procedure in STEP A for driver and passenger doors. Confirm a complete adhesive seal when replacing waterproof film. PAGE 5 of 8

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9 INSTALLATION TEMPLATES PAGE 9 of 8