KWIK-KIT KK-S-120-02 INSTALLATION INSTRUCTION PACKAGE
INSTALLATION INSTRUCTIONS HAVIS KWIK-KIT KK-S-120-02 2002-2007 DODGE/FREIGHTLINER SPRINTER VAN PLEASE READ COMPLETE INSTRUCTIONS PRIOR TO INSTALLATION TOOLS NEEDED: Standard open-end wrench set Power drill 3/8 Standard socket set 3/8 Ratcheting wrench Drill bit set Caulk gun Screwdriver set Allen wrench set HSEC KWIK KIT HARDWARE (STANDARD FOR ALL KITS) QTY DESCRIPTION PART # A. 120 ¼-20 x ¾ Hex head bolts GSM33001 B. 100 ¼ Flat washers GSM31005 C. 150 ¼-20 Hex flange serrated nuts GSM30023 D. 65 #10 x ¾ Sheet metal screws GSM33151 E. 85 #10 x 1 Sheet metal screws GSM33196 F. 35 ¼ x 1 Hex head lag bolts GSM33060 G. 45 ¼-20 x ¾ Carriage bolts GSM32000 H. 2 Tubes of silicone PRM97343 I. 4 Lock keys PRM97660-1 J. 5 3/8-16 x 2 Hex head tap bolt GSM33032-1 K. 6 3/8-16 Hex nuts GSM30008 L. 6 3/8 Lock washers GSM31028 M. 12 3/8 Flat washers GSM31007 Seat belt or grab strap hardware. N. 15 ½-13 x 1 ¼ Button head bolts GSM33310 O. 15 ½ Lock washers GSM31030 P. 15 ½ Flat washers GSM31009 RECOMMMENDED TORQUE BOLT VALUES: 1. ¼-20 Grade 5 hardware 8 foot lbs. 2. 3/8-16 Grade 5 hardware 25 foot lbs. 3. ½-13 Grade 5 hardware 60 foot lbs. REAR AND SIDE STEP KITS: (See Step Instructions) Includes steps and hardware. DOME LIGHT KIT: Includes Dome Lights, Guards, and Wiring Kits. SEAT BELTS KIT: Includes Standard Grab Straps or Optional Seat Belts. DOOR STOP KIT: H:\KwKit\KK-S-120\
KWIK KIT MAIN COMPONENTS: QTY DESCRIPTION ITEM # 1 Rear Bulkhead w/ Double Door Item AA 2 Side Walls Items B-1, B-2 2 Benches Items C-1, C-2 1 Front Bulkhead W/ Emergency Exit Item D 1 Main Floor (Kit Specific) Item E 1 Drivers Side Ceiling Section Item F-1 1 Passenger Side Ceiling Section Item F-2 1 Divider Item H 1 Rear Floor Filler Item I 1 Driver Side AC cover panel Item O 1 Passenger Side B Pillar Filler Panel Item Q 1 Driver Side B Pillar Filler Panel Item R Not Shown 1 Ceiling Filler Panel Item S Not Shown 2 AC / Heat Cover Mounting Angle Not shown 2 Front Bulkhead / Door Frame Plates Not Shown 2 Rear Door Frame / Step Brackets Not Shown 2 Door Stops Not Shown CAUTION: Installation of Kwik Kit Units require the entire unit to be loosely assembled (hand tightened) prior to fastening to floor of vehicle. Entire unit must be bolted to itself, squared, and in its proper location. INSTALLATION INSTRUCTIONS: 1. PREPARATION: Remove all parts from shipping pallet and confirm receipt of all parts. Strip inside of van. Remove interior floor mat, spare tire and jack, and factory bulkhead if equipped. (Fig 1) Leave 5/8 plywood flooring. Complete all wiring for lights, fans, HVAC, etc. at this time. Run HVAC hoses at this time and leave enough length so they can be routed through side of driver side bench to location where condenser will mount. See HVAC installation instructions. Install Rear and Side Steps at this time. Be sure to install Rear Bulkhead support brackets while installing Rear Step. See Step instructions. WIRING SPECIFIC INSTRUCTIONS: Located in front of OEM battery is an auxiliary fuse panel and (1) empty slot for your needs. This empty slot is the only factory recommended power source for 12volt accessories being installed into Sprinter Vans. (Fig 2) Up to 150 amp fuses may be purchased from Dodge / Freightliner to accommodate all accessories. Fig 1 Fig 2 Page 3
There are also 25 amps of 12volt power available under drivers seat. To access this you must remove driver s seat from its base. 2. BULKHEADS: Rear Bulkhead: (Item AA). Place inside van. Load through side doors. Be sure locking hardware is facing rear of van. Bulkhead will be positioned behind rear wheel wells. Center post of rear bulkhead must be removed at this point save for reinstallation. (Shown installed in Fig 8, page 5) Block doors into open position. Front Bulkhead: (Item D). Place Bulkhead inside of van. Load through side doors w/ quick pin locks facing towards front of van. (Fig 4) 3. BENCHES AND WALLS: (Items B-1, B-2, C-1, C-2) Pre-Assemble and completely tighten outside of vehicle, using ¼ Hex head bolts, washers, and nuts. (Hardware A, B, C) (Fig 3) ASSEMBLED 2 PC WALL BENCH Shown w/ Optional KK-BLT Seat belts Fig 3 Fig 4 Note: Bench is properly positioned when it is centered on wall. Wall overhangs bench by 1 ½ on each end. Bolt seat belts or grab straps at this time using ½ Button head bolts, Flat washers, Lock washers, and nuts. (Hardware N, O, P). Note: If straps or belts are not installed hardware must still be installed to fill holes. Place assembled wall and bench in van, position to rear of van. Note: Walls and bench assembly will slide into vehicle from rear of van through open doors of rear bulkhead. Loosely bolt driver side Wall and Bench assembly to Front and Rear Bulkheads. Loosely bolt passenger side Wall and Bench assembly to Rear Bulkhead - (Hardware A, B, C) (Fig 5) Page 4
4. FLOORING: (Item E) Main Floor can be placed in van through Rear Bulkhead w/ doors open. Kwik Kit assembly may have to be moved to position this floor properly. When properly positioned - floor lies on top of bench flanges and covers vehicle floor. Floor fits tight to benches and Bulkheads. (Fig 6) FRONT OF VAN MAIN FLOOR PLATE FLOOR (ITEM E) 5. CEILING: (Items F-1 / F-2) Slide both halves of ceiling on top of assembled cage and wall units starting w/ Driver side (Item F-1). Passenger side ceiling, (Item F-2), is overlapped by driver side. (Fig 7) Pull wiring for ceiling lights at this time. (If using KK -AC option, revert back to those instructions at this time.) ITEM F-1 ITEM F-2 Fig 7 Fig 8 6. DIVIDER WALL: (Item H) (Fig 8) Identify and determine ends of Divider Mounting angle that runs along top and bottom of Divider will face driver side of Kwik Kit. Locate and center Divider - front to rear and top to bottom. Using same hardware from earlier removal, reattach center doorpost to Rear Bulkhead. Rear Bulkhead has (2) holes centered above escape hatch and (2) holes centered below escape hatch. Bolt divider to Rear Bulkhead using ¼ Carriage bolts and Serrated nuts. (Hardware C, G) Front Bulkhead has (2) holes centered above doorframe. Page 5
Bolt divider to front bulkhead using ¼ Carriage bolts and Serrated nuts. (Hardware C, G) Check for door alignment and function. 7. ROUTE KK-S-HVAC HOSES: Cut 4 hole into front lower right hand corner of driver side bench. Route HVAC hoses; run earlier, into Kwik Kit. Mount HVAC unit. Refer back to KK-S-HVAC instructions at this time With HVAC unit installed, place 3 rd compartment bench against Divider Wall and Front Bulkhead. Remove HVAC access panel on 3 rd compartment bench. 8. SQUARING UNIT TO ITSELF: Kwik Kit is now self-supporting and ready to be tightened to itself, it is still not attached to vehicle yet. CHECK: Main Floor (Item E) is tight against Benches (Items C-1 / C-2) for length of vehicle. Rear Bulkhead (Item AA) is square to Ceilings, walls and benches. Edges and break lines of Walls and Benches should align w/ edges and break lines of Bulkheads and Ceilings. Doors on Kit close and align properly to Door Frames and latch to pins. Start to tighten all loose bolts on unit monitoring squaring points highlighted above. RECOMMMENDED TORQUE BOLT VALUES: 1. ¼-20 Grade 5 hardware 8 foot lbs. 2. 3/8-16 Grade 5 hardware 25 foot lbs. 3. ½-13 Grade 5 hardware 60 foot lbs. At end of this step, unit is completely self-supporting and tightened to itself. Complete final check of door operation. 9. ATTACH CEILING TO WALL: (Items B-1, B-2 to C-1, C-2) Shift Ceiling pieces so flange of Ceiling is flush w/ Wall. Divider may cause this to be a bit tight. Attach Ceilings to Walls of Kwik Kit assembly, starting in center and using #10 x ¾ Sheet metal Screws. 5/32 pilot holes will be required. (Hardware D) Note: A drill stop is recommended when pre-drilling ceiling to avoid dimpling outside of vehicle or hitting wiring that runs along corner of vehicles ceiling. 10. SECURE KWIK KIT UNIT TO VEHICLE: Note: This will be first Item that gets secured to vehicle. It is very important that all components are in proper location and Walls, Ceiling, and Bulkheads are bolted to each other and tightened. This must be completed prior to next step! 11. SECURE BULKHEADS: (Items AA, D) Page 6
Front and Rear Bulkheads may now be secured to vehicle. (See Figs 9 & 10 for proper positioning.) Check again that Bulkheads are located w/ Doors functioning properly. Rear Bulkhead frame is 7 from edge of trim or 3 ½ from rear edge of plywood floor and centered in vehicle. Front Bulkhead should be 12 ¼ from rear of front seat base and centered in vehicle. Rear Bulkhead Measurement Front Bulkhead Measurement Factory Trim 7 Front Seat Base 12¼ Rear Bulkhead support brackets bolt to Rear Step Brackets as shown below using ½ bolts, washers, and nuts. (Hardware J, K, M, L) (See Figs 11 & 12.) Front Bulkhead Mounting Plates are used as a re-enforcements to floor of vehicle as shown on following page. With Bulkheads positioned drill 3/8 holes through floor of vehicle. On Rear Bulkhead these holes will line up w/ Rear Support Brackets install in previous step. Bolt Rear Bulkhead to vehicle using 3/8 x 2 Hex head tap bolts, nuts, washers, and Support Brackets. (Hardware J, K, L, M) Drill 3/8 holes in Bulkheads. Attach Front Bulkhead to vehicle using 3/8 x 2 Hex head tap bolts, nuts, and, Mounting Plates. Rear Bulkhead Support Brackets Front Bulkhead Mounting Plate Support Plate ½ Hardware 3/8 Hardware Rear Step Bracket HVAC Hoses Page 7
Read very carefully before following the next set of instructions!!! Check position of pilot holes before drilling through floor of vehicle, insure that vehicle components, (gas tank, drive train, wires, etc.), will not be penetrated. 12. SECURING MAIN FLOOR: (Item E) Drill 3/16 holes through Floor and Bench flanges (10 on each side). Then drill 1/8 pilot through floor of van and use #10 x 1 Sheet Metal Screws (Hardware E) to secure Floor and Benches to floor of van. Bolting Divider to: Bulkhead & Center Post. Centered between divider wall and bench, drill (10) 3/16 holes through diamond floor. Then drill 1/8 pilot holes into floor of van and secure using #10 x 1 Sheet metal screws. 13. FASTEN DIVIDER WALL: (Item H) 1 st CHECK: Doors still align to Pins on Center Post. Note: Alignment of doors will determine location of Center Post, which will then determine location of Divider wall. 14. FINISH Check for door alignment and then fasten Divider Wall to Main Floor by drilling 3/16 pilot holes using ¼ by 1 Hex Head Lag Bolts. (Hardware F) Mount to Ceiling following same procedure. Bolt Divider Wall to Center Post. Drill (5 per side) ¼ holes through Center Post and Divider Wall flange. Attach using ¼-20 x ¾ Hex head bolts and ¼ Serrated nuts. Fasten Divider to Front and Rear Bulkheads using ¼-20 x ¾ Hex Head Bolts, Washers and Nuts (Hardware A, B, C) (Fig 13) Mount A/C Cover on driver & passenger side of Kwik kit unit using #10 x ¾ Sheet metal screws. 5/32 pilot hole required. (Hardware D) Mount dome lights, power vent covers (optional), intercom (optional), and/or air exchange (optional). #10 Machine Screws ¼ Hex Bolts Apply Foam padding to Front Bulkhead as shown in (Fig 14). Attach door holder assemblies. Install HVAC unit Cover using #10 x ¾ Sheet metal screws. 5/32 pilot hole required. (Hardware D) Attach Passenger side B Pillar filler to front bulkhead using slots in partition. (Item Q) Fig 13 Foam Padding Screw Passenger side B Pillar filler to B pillar using #10 x ¾ Sheet metal screws. Attach Driver side B pillar filler panel to front bulkhead using existing hardware. (Item R) Attach Ceiling filler panel to front bulkhead using existing hardware. (Item S) Bench and wall protective paper can be removed at any time. Clean out inside of Kwik Kit unit. Tubes of silicone are supplied to seal seams. Fig 14 Page 8
ASSEMBLED VIEW OF SPRINTER DUAL COMPARTMENT KWIK KIT Items R and S mount in the top and driver side of the front bulkhead similar to Item Q Page 9
Items R and S mount in the top and driver side of the front bulkhead similar to Item Q Item R Item S Item D Item F-1 Item B-1 Item C-1 Item F-2 Item H Item B-2 Item AA Item E Item I Item C-2 EXPLODED VIEW OF SPRINTER DUAL COMPARTMENT KWIK KIT Page 10