INSTALLATION INSTRUCTIONS KK-K9-C12-K CHEVY IMPALA

Transcription

1 INSTALLATION INSTRUCTIONS KK-K9-C12-K CHEVY IMPALA READ ALL INSTRUCTIONS PRIOR TO INSTALLATION TOOLS REQUIRED: Power Drill Drill bits1/4 and 5/32 7/l6 wrench and socket 15,18 and\or 19mm socket Ratcheting Wrench Phillips screwdriver or driver tip Wire cutters / crimping tool Caulking gun Tin snips T-30 Torx Bit HARDWARE SUPPLIED WITH THIS KIT: QTY: PART NO: DESCRIPTION: 10 GSM33150 #10 x ½ Flat head Screw 34 GSM34169 #10 x ½ Stainless Screw 40 GSM34151 #10 x ¾ Stainless Screw 29 GSM32022 ¼ x ½ Stainless Carriage Bolt 12 GSM32024 ¼ x ¾ Stainless Carriage Bolt 47 GSM30023 ¼ Serrated Nut 6 GSM ¼ x ¾ Lag Bolt 4 GSM33001 ¼ x 1 Hex Head Bolt 4 GSM31005 ¼ Flat Washer 10 GSM34169 #10 x ½ Stainless Screw 112 GSM35100 Edge Molding With Rubber Gasket 102 PRM97622 Edge Molding 1 PRM97343 Tube Silver Silicone COMPONENTS SUPPLIED WITH THIS KIT: QTY ITEM # DESCRIPTION 1 ITEM A Front Cage 1 ITEM B Rear Cage 1 ITEM C Floor 1 ITEM D Ceiling 1 ITEM E Rear Deck Filler Plate 2 ITEM F Upper Front Filler Panel 2 ITEM G Lower Front Filler Panel 2 ITEM H Step Sill Trim 2 ITEM I Lower Rear Filler Panel 2 ITEM J Upper Rear Filler Panel 2 ITEM K Rear Cage Bracket 2 ITEM L Front Cage Bracket (2 Piece) 2 ITEM M Door Panel 2 ITEM N Hinged Window Guard 1 ITEM O Dome Light Kit 1 ITEM P Rubber Mat

2 ITEM J ITEM F ITEM D ITEM E ITEM G ITEM B ITEM K ITEM I ITEM A ITEM C ITEM L ITEM H *ALWAYS CHECK FOR GAS AND FUEL LINES, WIRE HARNESSES, AND OTHER OBSTRUCTIONS BEFORE DRILLING ANY HOLES! INSTALLATION PROCEDURES: 1. REMOVE NECESSARY INTERIOR TRIM PARTS. Rear seat (bottom and back) Door panels. Note: If door has electric lock and/or window controls, the switches must be reconnected to original plugs. The switch assembly must be wire tired to inner door panel so as not to interfere with the window or lock mechanisms. Door lock pin assembly Rocker panel (step sill) trim Seat belts remove center back seat belt latch and buckle Place floor into vehicle to rearmost position and center. Window Controls 2. MOUNT REAR CAGE. Outside of Car, attach Rear Deck Filler Plate to rear cage with ¼ x ½ Carriage bolts and ¼ serrated nuts. Place cage on top of floor, in front of floors rear flange. Center and attach with #10 x ¾ Sheet metal screws. Use 5/32 drill bit for pilot holes.

3 Attach Rear Cage Brackets to existing holes in cage with ¼ x ½ carriage bolts. Bolt bracket to body as shown. Mark and drill ¼ hole and attach with ¼ x 1 Hex head bolt, washer, and serrated nut (one per side). Note: Do not tighten bolts and nuts at this time. Wait until main components are properly positioned. 3. MOUNT FRONT CAGE. Place cage on top of floor behind front floor flange. Attach to floor with ¼ x ½ carriage bolts (loosely install only two bolts at this time). 4. MOUNT CEILING. Make sure rear cage window is hinged down. Place ceiling on top of front and rear cages. Attach loose with ¼ x ½ carriage bolts. Be sure that ceiling and cage flanges are flush to each other then tighten. Attach the 2 piece Front Cage Bracket. Start with the piece that attaches to cage first using ¼ x ½ carriage bolts and serrated nuts. Lineup the two bracket pieces to B pillar trim. It should land between the upper and lower trim pieces. Mark and notch plastic trim. (Notch can be done using tin snips or utility blade). Attach tapered bracket to inner steel B pillar. Mark the three holes and drill a 5/32 pilot hole. Attach with three ¼ x ¾ lag bolts. Connect bracket pieces together using ¼ x 1 hex head bolts, washers and nuts. 5. INSTALL STEP SILL TRIM (one per side) Position trim to fit tight with long contoured flange towards rear. Make sure trim is pushed down into weather stripping. The contoured flanges should fit with minimum gaps. Mark and drill 5/32 pilot holes. Attach with six (6) #10 x ¾ Sheet metal screws. (3 per side)

4 6. LOWER REAR FILLER PANELS Position filler to fit tight, mark, and pre-drill with 5/32 pilot holes. Attach to rear cage with three (3) #10 x ¾ Sheet metal screws. Attach to step sill trim with two (2) #10 x ¾ Sheet metal screws. Drill 3/16 holes into the lower rear filler and 5/32 holes into the step sill trim. Note: Apply pressure to panels while installing in order to get a tight fit. The lower rear filler will fit over the step sill. 7. UPPER REAR FILLER PANELS Position filler to fit tight, mark, and pre-drill with 5/32 pilot holes. Attach to rear cage, ceiling and lower rear filler panel with six (6) #10 x ¾ Sheet metal screws. 8. EDGE MOLDING Attach rubber edge molding to Filler Panels as desired. 9. DOOR PANELS (OEM panels removed in step #1) Center so edges do not hang over. Mark and drill 5/32 pilot holes. Attach to door with #10 x ½ Sheet metal screws. 10. HINGED WINDOW GUARDS Hold window guard with pre-assembled hinge and upper bracket onto window frame. Make sure guard is centered on window. Attach hinge to lower door panel with #10 x ½ Stainless sheet metal screws. Mark upper aluminum bracket location on window frame and remove from window guard. Drill 5/32 pilot holes. Attach aluminum bracket onto window frame with #10 x ½ flat head screws. Hinge up window guard and reattach to bracket with x ½ machine screws. Note: This is for easy window cleaning. 11. LOWER FRONT FILLER PANELS Position filler and attach loose with three (3) ¼ x ¾ carriage bolts. Close corresponding door and allow for minimum gap then tighten Note: Step trim flange should be forward of this panel.

5 12. UPPER FRONT FILLER PANELS Note: The filler panel with a notch, is for the passenger side. Position filler with corresponding door closed. Mark and drill through filler and cage with ¼ drill bit. Attach fillers with ¼ x ¾ carriage bolt and serrated nut. 13. INTERIOR COMPLETE Be sure that optional water bowl bracket has been mounted. Peel off clear plastic coating on aluminum pieces. Vacuum or blow out all trash and metal shavings created during install. 14. SILICONE All gaps and seams must be sealed in order to shed water out of the compartment onto the ground. 15. RUBBER MATTING After silicone is dry, place in rubber matting. 16. DOME LIGHT See attached dome light instructions.