GENUINE PARTS INSTALLATION INSTRUCTIONS

Transcription

1 GENUINE PARTS INSTALLATION INSTRUCTIONS DESCRIPTION: APPLICATION: PART NUMBER: KIT CONTENTS: Tow Hitch Finisher Pathfinder (2013) 999T5 RZ030 Installation of this accessory requires installation of additional parts: Trailer Tow Hitch (999T5 RZ100) Trailer Tow Harness (999T8 YZ000) Item Qty. Part Description Service Part Number A 1 Tow Hitch Finisher B 1 Cutting Template C 1 3M Adhesion Promoter 4298 D 2 Spring Nut E 2 Screw F G 3 1 Spring Clip Installation Instructions Replacement Template 999V2 AW000 A B C D E F G TOOLS REQUIRED: Cutting tool: RotoZip tool or a small reciprocating air saw with short, fine tooth blade. See images below. Drill with drill bit Flathead screwdriver Masking tape Protective gloves Phillips screwdriver 90% or greater isopropyl alcohol Clean, lint-free cloth Safety glasses with side shield Utility knife PRE-INSTALLATION CRITICAL STEPS and NOTES: Dealer installation recommended. Instructions may refer to Service Manual. Parts to be installed at room temperature. Page 1 of 6 999T5 RZ030II Rev. 06/20/2012

2 INSTALLATION PROCEDURE: Fig. 1 Before proceeding further, confirm installation of the following part has been started; 1) Trailer Tow Harness (999T8 YZ000) Raise Vehicle on hoist to working height. 2) Use a clean, lint-free cloth and clean installation surface (shaded area) with isopropyl alcohol and water solution. Use at least 90% alcohol solution. Allow the alcohol to dry completely. Fig. 2 3) Use a flathead screwdriver to remove two (2) trim clips from the under side of the bumper. Save trim clips for next step. Fig. 3 4) Position the cutting template(b) to the rear bumper. Line up the trim clip holes on the rear bumper and the holes in the cutting template. Reinstall the two trim clips previously removed in step 2. Page 2 of 6 999T5 RZ030II Rev. 06/20/2012

3 Fig. 4 Apply pressure to be sure template is positioned firmly against the bumper surface. 5) Apply masking tape around all outside edges of template to secure it to bumper, as shown in fig 4. CAUTION Safety Glasses required beyond this step. 6) Drill holes as shown in Fig 5 below. See Detail A & B. Fig. 5 Detail "B" Drill hole as shown(2 places) Detail "B" Drill Two (2) holes as shown Page 3 of 6 999T5 RZ030II Rev. 06/20/2012

4 7) Remove any tape that covers inside edge of template. 8) Drill holes at locations shown in Fig 6 using 6mm bit. This will help cutting process in the following steps. Be sure Drill Bit is slightly below or lightly touching inside edges of template. Fig. 6 Inside Edge 9) Use RotoZip tool or small reciprocating air saw with fine tooth blade to cut the bumper plastic and connect the holes previously drilled in step 8. Follow the edge of the template and work carefully from one hole to the next until complete. Make sure to cut the excess materail in the slot locations(reference figure 5 in step 6). During the cutting process move slowly and firmly keeping the cutting bit/blade close to template. To minimize burrs left on rear bumper cut bumper material in a counter-clockwise Cutting tool Start cutting here. Be aware of vehicle parts behind bumper in this area. Fig. 7 Page 4 of 6 999T5 RZ030II Rev. 06/20/2012

5 Fig. 8 12) Remove cutting template by removing all masking tape and remove the two trim clips from template. 13) Re-install trim clips to attach bumper to metal brackets(behind bumper/fascia). Confirm slot widths shown in Detail A & B below are between 6 & 7 mm. If required use a coarse file to remove material until the slot is between 6 and 7mm. Drill hole as shown(2 places) After cutting slots, use a file to remove burrs. Drill Two (2) holes as shown Detail "B" Minimum 7.0mm Maximum Minimum 7.0mm Maximum Before starting next step, confirm installation of the following parts has been completed: Tow Hitch Receiver (999T5 RZ100) Tow Hitch Harness (999T8 YZ000) 14) Clean installation area(shaded area) using a clean, lint-free cloth with isopropal alcohol and water solution. Use at least 90% alcohol solution. Allow the alcohol to dry completely before continuing the installation process. Fig. 10 DO NOT use clips at this time. 15) Firmly position the Hitch Finisher(A) against bumper. The three tabs on the back of Finisher will align with 3 slots in bumper. Use a #2 pencil to lightly mark the bumper (see figure 10). Hitch Finisher Page 5 of 6 999T5 RZ030II Rev. 06/20/2012

6 Pencil mark Fig ) Apply masking tape to match up with pencil marks(see figure 11). This will protect visible areas from adhesion promoter. Fig ) Apply a thin layer of adhesion promoter(c) to shaded area(see figure 11). Remove the masking tape immediately and wait a minimum of two minutes before continuing the installation process. The installation process should be completed within one hour of applying the adhesion promoter. Insert Three (3) Spring Clips into Bumper Slots Fig ) Wear hand and eye protection when working with adhesion promoter. Insert 3 spring clips(f) into the slots in the bumper(see figure 12).Make sure clips(f) are centrally located in the slots. Spring Nuts 20) 21) Install 2 spring nuts(d) over holes on the under side of bumper. Flat surface of nut should be facing the ground. Hole in spring nut must line up with hole in bumper(see figure 12). Fold back red tabs on tape so they are expose(see figure 13). Do not peel tape at tis time. Pull tabs Fig. 13 NOTE: DO NOT peel tape at this time. 22) Position the Hitch Finisher against the bumper and press firmly to engage all three posts on the Hitch Finisher(A) into the three spring clips(f) in the bumper. 23) Carefully lift the outer edges of the finisher and peel back the red pull tabs on the tape. Fig ) Use a roller or burnish by hand with a cloth to apply a minimum of 15lbs force along length of tape. Repeat this process three times per side. 25) Install two screws(e) into the spring nuts in the bottom of the bumper (see figure 14). Torque the screws to Nm (10-13 in-lb). Screws Page 6 of 6 999T5 RZ030II Rev. 06/20/2012