2 Rubber Bumper GSM MM nut GSM30201 K9-F18-PT_INST_4-16

Transcription

1 K9-F18-PT INSTALLATION INSTRUCTIONS K9 Kit for FORD INTERCEPTOR UTILITY Vehicle Notes: 1. For K9 applications, it is recommended to order the Interceptor Utility with the OEM optional Aux Rear Air conditioning. (Ford option code 17A) 2. The OEM optional Reverse Sensing System (76R) uses the driver side passenger door speaker for the audio warning. Audio for this option will be lost when speaker is removed for K9 door panel. If this feature is desired, relocating the OEM speaker or using another type of speaker is the responsibility of the installer. TOOLS Needed: Phillips Screw Driver Trim panel removal tool Caulk Gun Standard Socket set Metric Socket set Wire Cutters /Crimpers Plastic cutting tool PARTS & HARDWARE: QTY DESCRIPTION PART # 1 Front K9 wall with sliding door KNM K9 front wall upper B pillar bracket KNM K9 floor KNM K9 front floor bracket KNM K9 middle floor bracket KNM K9 rear floor bracket KNM K9 rear wall KNM K9 side wall ( L shape) KNM K9/PT divider wall with sliding door KNM K9/PT divider wall lower filler panel KNM K9 ceiling KNM K9 top rear filler panel KNM K9 upper filler (large) KNM K9 upper filler (small) KNM K9 lower filler panel KNM K9 side floor filler KNM PT front wall KNM PT front wall upper B pillar bracket KNM PT front wall lower B pillar bracket KNM PT front wall lower filler kick panel KNM PT front wall upper clear guard KNM PT rear wall KNM PT rear wall upper support bracket KNM PT rear floor filler plate (behind wall) KNM K9 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 K9-A /4 serrated flange nut GSM /4 Flat washer - SS GSM /4 x 3/4 Carriage bolt SS GSM /4 x 3/4 Phillips pan head screw - SS GSM #10 x 1 Phillips pan head sheet metal screw GSM /4 Nylock nut 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 mm x 35mm Hex bolt GSM /16 Lock washer GSM /16 Flat washer 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. K9-F18-PT Assembly (Door panels and window guards not shown) KNM PT rear upper support bracket KNM PT side clear guard/shield KNM PT rear wall KNM rear floor filler plate (not shown) KNM Ceiling KNM Rear K9 Wall KNM K9 top rear filler panel KNM PT front upper B pillar bracket KNM K9 upper large filler KNM PT front lower B pillar bracket KNM K9 upper small filler KNM PT front wall KNM K9 Side wall KNM K9 front B pillar bracket KNM PT front lower filler kick panel KNM PT lower side filler panel KNM K9/PT divider wall assembly KNM front floor bracket KNM middle floor bracket (not shown) KNM rear floor bracket (not shown) KNM K9 front wall assembly KNM Side floor filler panel KNM K9 lower filler panel KNM K9 Floor KNM K9 rubber mat Door Panels and Window guards not shown

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) Note: OEM optional Reverse Sensing System (76R) uses the driver side passenger door speaker for the audio warning. Audio for this option will be lost when speaker is removed. 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. 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. Seats and cargo floor now removed. Run wiring as needed. Use OEM seat nuts and bolts to attach the forward floor mount bracket to seat mount location on driver side. Attach rear floor mount bracket to cargo floor filler location with two (2) 8mm x 35mm hex head bolts, 5/16 flat washers and lock washers. If using C-TTP-INUT-1 or 200, this bracket will not be used. K9 floor will attach directly to the trunk tray. Remove the small side seat bracket located near the driver side door and wheel well. Remove one (1) nut from OEM center support bracket. Attach middle floor bracket to floor with OEM bracket hardware. Tighten all floor bracket hardware. Place K9 floor onto floor brackets. Loosely attach to front and middle brackets with 1/4 x 3/4 carriage bolts and serrated flange nuts.

6 Place rear wall on floor with flanges forward and loosely attach to floor bracket with 1/4 x 3/4 Phillips pan head stainless steel screws and flat washers. (hardware also goes through floor) Loosely attach K9 front wall to floor with 1/4 x 3/4 carriage bolts and serrated flange nuts. (nuts on front side) Remove OEM B pillar grab handles on both sides. (save hardware) Loosely attach front wall to B pillar with 5.25 long L bracket using 1/4 x 3/4 carriage bolt and flange nut. Attach to B pillar grab handle location using OEM hardware. Place side wall on floor and loosely attach to floor and rear wall with 1/4 x 3/4 carriage bolts and serrated flange nuts. Loosely attach K9 lower filler panel to floor with 1/4 x 3/4 Phillips head screws and flat washers. Attach to side wall with 1/4 x 3/4 carriage bolt and serrated flange nut. Loosely attach divider wall to floor and rear wall with 1/4 x 3/4 carriage bolts and serrated flange nuts. Loosely attach the ceiling to walls with 1/4 x 3/4 Phillips pan head stainless steel screws and flat washers. Loosely attach 4.25 long upper L bracket to B pillar grab handle location (passenger side) using OEM hardware. Loosely attach lower passenger side C shape bracket to B pillar grab handle location using OEM hardware. Loosely attach PT front wall to divider wall, K9 front wall and B pillar brackets using 1/4 x 3/4 carriage bolts and flange nuts. Note: The PT front wall wraps around the front of both other walls. (nuts in driver compartment)

7 Loosely attach divider wall lower filler panel to floor with four (4) 1/4 x 3/4 Phillips head screws and flat washers. Attach to front wall with 1/4 x 3/4 carriage bolt and serrated flange nut. Loosely attach lower PT front wall filler panel to wall with 1/4 x 3/4 carriage bolts and serrated nuts. Note: forward side of panel has holes for bolting to floor if desired. This may not be necessary. There should be no obstacles under floor, but always double check. Loosely attach rear PT wall to divider wall with 1/4 x 3/4 carriage bolts and serrated nuts. Note: Smooth head of bolt goes inside the K9 compartment. Loosely attach the PT rear support bracket to the rear wall with a 1/4 x 3/4 carriage bolt and serrated nut. Temporarily remove upper door gasket. Mark and cut slot in plastic trim so bracket can be attached to C pillar. Pull trim back slightly and drill 5/32 holes in C pillar for mount screws. Attach with # 10 x 3/4 Phillips sheet metal screws. Tighten bracket hardware and replace rubber door gasket. Re-install OEM passenger seat. Bolt the clear upper guard to PT front wall if desired with 1/4 x 3/4 carriage bolts and serrated flange nuts. Cut out plastic for ticket pass thru if desired. Note: Be aware that the guard may minimize ventilation. Loosely attach upper large filler panel to ceiling with three (3) 1/4 x 3/4 Phillips head screws and flat washers. Loosely attach upper filler panel to front wall with one (1) 1/4 x 3/4 carriage bolt and serrated nut. Loosely attach top rear filler panel to ceiling and side wall with four (4) 1/4 x 3/4 Phillips head screws and flat washers

8 Loosely attach small upper filler to large filler and side wall with three (3) 1/4 x 3/4 Phillips head screws and flat washers Adjust parts and tighten all hardware at this time. Attach side floor filler to floor two (2) 1/4 x 3/4 Phillips head screws and flat Attach rear floor filler plate to rear wall and rear floor bracket with four (4) 1/4 x 3/4 Phillips head screws and flat washers. Mount 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. Example of side tunnel mounting location for the optional 10 exhaust fan kit Part Number - K9-A-301 NOTE: 12 fan Not recommended for the Interceptor Utility. Optional driver side window guard / fan mount shown. Fan mount kit part number K9-A-104 **Kit includes K9-A-301 fan and WGI mount with hardware** One example of how a gas spring can be mounted for the optional K9-A-201 Hot-N-Pop system. Mounting location for gas spring to be determined by the installer. Neatly silicone / caulk the lower seams of walls and floor to shed water out of vehicle. Install rubber mat when silicone is dry. Position clear polycarbonate upper guard on prisoner side of PT front wall and drill mount holes in plastic. Bolt on with 1/4 x 3/4 carriage bolts and serrated nuts.