I

I

FOR WINTERIZATION

KITS

VEH 14067741 14067742 14067743 14067744 1 2 3 4 TYPE TYPE TYPE TYPE TYPE 008 MI031 "E" MI028 It MI009 IiCII 010
II

"BII

-

CARGO SHELT CAB CHASSIS CARGO SHELTER UTILITY

ROOP SEAT CARRIER

4-55 56-64 65-73 7 75 76-82 83 84-88 89 90-93 94 95-126 12 132

INSTALL ENGINE PARTS LIST INSTALL PARTS WINTER ST

HEATERS COMPARTMENT (MI009) SULATOR ( 009)

INSTALL ILTED COVER PARTS LIST INSTALL PARTS LIST INSULATOR

INSTALL INSULATOR PARTS LIST INSTALL WINTER PARTS LIST MANUFACTURING

UNIT RADIATOR COVER

AND HOOD

CARGO

(MI008

A JACKNUT

TOOL

ALL ITEMS REMOVED AND REPLACED WITH NEW PARTS SHOULD BE IDENTIFIED AND RETURNED TO STOCK FOR USE AS SERVICE PARTS, SUCH AS OIL COOLER LINES, OIL PAN, TRANSMISSION PAN, BATTERY TRAYS, HEATER BLOWER ASSEMBLY, ENGINE COOLANT CROSSOVER, CARGO BOX TAILGATE AND HARDWARE. OTHER PARTS (WATER HOSES AND OLD INSULATORS) MAY BE DISCARDED. HOW TO USE PARTS
1

LIST. IN EACH FIGURE {SHOWN IN WHICH

REFER TO PICTURE I SHOWN IN EACH READ A. B.
S.

NUMBER ION. AT THE

2.

END OF EACH SECTION.

FIND THE BOX NUMBER

C.

FIRST COLUMN IS ITEM NUMBER PTION. SECOND IS THIRD COLUMN IS PART NUMBER (EACH PART PART NUMBER). 1-

IS TAGGED ,

BY ITS OWN

2

e2 CONTENTS-MILITARY (conti ) D. INSTALLATION IONS FOR WINTERIZATION KITS

E.

FOURTH COLUMN IS THE UNIT BOX THAT THE PART IS PACKAGED IN AND IS SUPPLIED IN THE KIT. IF THERE IS A NUMBER UNDER THE UN NUMBER IN PARENTHESES, EX. (12345678), THE PART IS IN THAT PACKAGE WHICH IS A INSIDE THE UNIT BOX. FIFTH COLUMN SHOWS WHICH KIT THE PART IS IRED FOR AND IS SUPPLIED IN THE KIT.

SPECIAL TOOLS IRED FOR INSTALLATION OF WINTER KITS WHICH ARE INCLUDED IN KITS: INSTRUCTIONS FOR MANUFACTURING A JACKNUT TOOL, SEALANT, TEFLON PASTE SEALER, AND ANTI-CORROSION SEALER.

RTV

ION OF WINTER KITS NOT INCLUDED SPECIAL TOOLS IRED I KITS: JACKNUT INSTALLATION TOOL, CAULKING GUN, HOLE SAWS IN THE INCH, 1-1 1 8 INCH, FOLLOWING SIZES: 1- 8 INCH, II INCH, INCH, AND 3 2 INCH.

IN

e3

DRilL 7/32" HOLE FOR II

BOLT

RADIUS IS

OPTIONAl.

" TO 1-1/4"

3/32" TO l/S" THICK

PROCURE

A 1/4"-20 #10-24

x

1-1

It

LONG HEX. HD

BOLT

(FULL THREAD) (FULL THREAD)

D PROCURE

x 1-

411 LONG HEX. HD. BOLT

BODY PANEL ANTI-CORROSION MATERIAL INSTALL JACKNUT INTO BODY DRILLED HOLE.

2. PLACE TOOL OVER NUT. INSTALL 1/4-20 BOLT AND TIGHTEN TO 30 LB,-IN. (3.5 Nml OR 0-24 BOLT TO 15 LB,-IN. (2.0 Nm). ANTI-CORROSION MATERIAL 3. REMOVE BOLT AND TOOL.

2

.1

' Remove Remove Remove Loosen oil ts securi ine and remove. Disconne bat eri t negative (-) hold down fasteners NOTE Save Remove to fe Its from tte down remove reinstallat remove 1ts Idi ttery t Remove 0 1 dipstick. E 7. care a low flui to drain. Remove remaini loose a d lts and remove e 1 • Remove f tti s on e ne i ure •) Remove bolt ne. remove nting tube a lout tube 6. Remove 6. ine coolant t nd s r from bracket ass ines from clip (F ure 15 . lines at Ie ly rear of ocated (Figure at 1 ) rear oi 12 Using s rewdr ver. HEATERS 1. ts 8.4 I . 2• inta leo a e (+) bat c plates and remove les from tteries. INSTALL Remove Cover INE air cleaner. Drai Remove e ne oi transmission to container dust cover. on oil pan bolts on front and sides of pan Its abou lly p 4 turns. ) • lines at lines Remove oil coola 0 eft side of radiator . later oil n to e tallation. nut and washer on di tick discard "0" ring seal. 1.. n rear seal from smiss ine block. 17 Remove (F g 1 1 oola from c ip on left fender ski t . 13. front of oil n. 9• O.

it is sea i on NOTE ad 29. ri i I Inst t 26. coo lines at t 1 . 9 Remove Remove Ins Ins Clean 9 a c ne 1 20. aces on b oil 2 lip of n winte rear bolts to bolts to z 24 25. 21 22. Id oil into new winteri pan.5 1 ter use 8.

-ft. 1. Connect new oil at rear mani T It a 1 nes a t r ran i f o Ld Remove existi bracket (F ure 1.0-35. Connect (Figure 1.0 Nm) (F ure 3. .). Install two new manifold Its a new bracket. (25. 34. Install to bracket. . oil coolant Ii Tighten 45new oil coolant F ure 1. o 19-26 lb. 2.i tal ine" t nes o..

).). smember to new winteriz n to pan outlet with attach amps an gure 3. t T ed new short e 1b •• ( 4 • 5 .7 • 0 Nm). an and new winterized ust pi (Figure 2. leE f T rear (11 0- .7 F 2.

•o.l t secure with h (11.-ft heate en •· .Page 8 PE.0 Nm).0-15. ENDS OF BEFORE CLAMPS TO 028. . 1031 NOTE 9 Ib.

e9 re .

transmi ra 41. Attach end of new fender brace in front of (Figure 5 n to 43.e 10 40. pipe. 28 and 1031 Vehic es. MI00S. st Ti in. . b t t ex ust F ure 5. Route r ht e new ater tailpi t pi (F 5. Attach wires and inj at rear of e ine wi st 42.

e 11 .

e 12

F 4. 5 al n peteoek

ure 5b. radia

M1010 Vehi

e.

and drain

itive (+) batte from plas c eli

, and remove

t on b from veh

e 13

Do not

11 on ter be cut off ter core outlets. hoses from firewall ine connect and e ri outlets, ns. cli on fender to r iator

46. Remove skirt 47. s 48. 49.
50.

Remove Remove

t front fender nder s er s rt to fe e

skirt er.

Remov r

51

1

e
53.

tr 1 connectors and remove let assembly (F ure 6.). rd toward firewall,

exis

ing blower

Bend we Clean

flange

3 inches

5.

firewa

1 area of old sealer.

55. Place new r inlet blower ass on firewall, and mark and drill a 32 inch Ie in left of assembly with missi ho e in firewall (F 6 ). Remove blower assembly after drilli hole. 56.

Install sealer on new air inlet blower assembly and install (F ure 6.). Tighten to 20-30 lb.-in. (2.3-3.4 Nm). ins r around sides of blower assembly

57. after

to new blower Tighten to 59. Install new existing electr 60 Transfer c from old blower motor
r to

to new blower motor.

2

1

e 14 61. Cut 2 i s off end of harness with electrical t 1 istor wire to

s

F 2. Remove us bar terminal

ure 6.

covers.
NOTE

63. Remove s irt.

studs

nd heater

hose clamp

from r

t fende

in right 5/16" 3/13" F 65. Locate fender s and in ure 7.P 64 fe Locate er skir drill 5/16 inch holes d ressions inch and (F ure 7 • ) • e 15 i les Y. 155 .). and 16 inch holes (Figure 8. in left 2 . as X. Y.

HOLE Figu .. HOLE 01.11.16 3/8" 5/16" OIA.

. F ure 9.e1 ST! 1 32 D A.

Remove ed as tai i screws (F ure 11 ) . 68.1 67. Loca te ill les in re o•)• Pi ts g glove box i y r as and remove gl NOTE i ts lye 71.

SCREWS ! ur e 11. .

e INSTRUME EL P 2" 3" . . .:'i ure 13.74.:I.

80 (F 81 (F Install Install Install Install I 21 6spri inch molding s for dash on ve retaini screws ded dash.-in.n. Tighten 2 . Feed control cable t h bracket and 21/32 inch hole in firewall. 1 0-2. 78. 14 and bolts ( in ed dash. remove Gover 82. assembly (Figure 14 ). 83. 79. and secure heater control assembly to bracket with screw nuts and washers and install grommet (Figure 14. u re 14 • ) heate lb.Page 76.0 Nm). r e 14 ).. Inst 1 cover on ater control to 8-15 Ib. 77.).

(1. and Remove rel from e ine air heater wiring harne s assembly ine coo ant heater wiring harness ass 1 (F ure 16.-in.).).2 s Nm). Usi drill to on he te 85. route engine as ly and ach wires through connec ion au side firewall ( ns a 1 gramme (Figure 14. hw lb.6-2. hood. irewall for and insta inst lat 89.e 22 84. 2 . Install (Figure 15.). air heater wir ss e in firewa eaving tee y 5 in s from Ie) nd 87.

). to dashboard (Pi ure 16 of eate engine efroster assembly air heater wir ng . bolt s~acer. 8 u r e 1 . harness 1 assembly along main alIef s vent to harness assembl control box (Pi re attaching ires h assembly s on on wi s into holes on eng air heate ture s fe switch in relay racket ttom f dashboard {2 inches u~ from box and install nut.e 23 ri rness re 16 ).

.

wiring harness assembly to fuse box rake area in holes 17 ly sealer to all grommets after seati . marked (Figure 97.Page 24 F 96. r heater r9 ure 16.

). Make sure the end of E iter marked 0 t et is pas tioned as shown in Figure 9. s NOTE e. flon pas sealer on pipe tread a er is required for flare fit i NOTE nlet-Outlet is marked on fuel f ter.)..). ns all Jacknuts Ear fuel fi ter on left acknut tool and bolts supplied (Fig r e 1 . 10 i . I. (F ne rs el LH th a ve shut-off and two c n ec 1 er- ure nsta fue 1 8. 100. Ass mble igu r e 1 . .(GROUND us BAR WARM HEATER AIR HARNESS FUSE 1 ~ J. a 8. nut required for fuel NOTE ump.

jac left inner fender with fitti on fuel .e2 102.

e 27 104. tach s rter 0 two fue Ii p and rou e along of firewall (F fitting to 152 lb. (20 • .0 Nm). 106. (20. 5.-ft.-ft.3 • 0 Nm). T hten 105. Install with screws switch ass Fi ure 18. Connect switch onnector on fuel 107. or 20 ) 1 i . 10 tach longer of two and rou e line along of fi fi ting to 5-20 lb. v c n. 10 . in.).0-27.). Install fuel (F ure 18. Instal j cknut in new cl a secure hten to 22-27 lb. vehi e (2. ines ) 1009.

e2 110.-in 19. . rame from or fe line at connect n on r t si e of Figure 20.). Tighten bolt to 19.0 Nm) (F ure 19. line to frame with (Figure 19. 19. or 20.). o Nm). Install new 1 0 lb. Install 96-1 1 112. or 20.). Tighten to 111. 114. or 20.). ru hose to long fuel line and fuel Tighten fittings to to both lines. or 20.

Assemb (F ure 21. tti MI031 cap a uel Ii ns a on " 11 n veh core outlets 30 1 in. 121. Install jacknut install clip on 1 (F ure 20. cl Install s Figure firewall n to 2 NO. C (Figure 118. fuel line on firewall NOTE 117 117. to short firewall. i e MI009. with 119.).) and tig 116.4 Nm).). Ie 120. Attach "T" fitti (Figure 19. Instal new and secure with cl (2. . 028.6-3.e 29 115. r 20.

.e 30 1031 1010 F ure 21.

(1.0 Nm). -11.-in. Install igure 22.) 130.5 (Figure 22. Install 150 lb.e 31 122.) 131 Install rac ets and c1 bolts and was rs F i ure . Assembl fuel filter and s Tighten to 10-13 1 to ackets t-off. .).0 Nm to front a Tighten to w . n 90" ittings Its to r on vehicle lb. 9. Install to 150 lb.-in.) . Install and bolts acknut tool E f se 1 f F III is 2 . Assemble connector.-in Its in fender (17.-ft. (8. to radiator fe T n 123. ( 125. va ve s fuel filte ( ure 22. Install 127. bol in fe (47. Install 35 lb. rews s er s i to 126.2-1.0 Nm). Install r ht fender skirt in vehicle. n ) skirt sk t T hten 124.

134 Remov r 22 housing. pe iator hose at thermostat ter pump to crossover cause brea ing 135 crossover t a head a ernator ground e. wire rc from move 0 cyl 137 from a racket mounting brac et right .e 32 Figure 33.

23 sion r tor a ve se to a cro sover i f s.1 . 1 2. Remove on crank remove i NOTE s Tef on se er case d e. Remove 11 gasket rna erial from r .e 33 13 Remove stud and bolt F gure 23 •• from crossover to righ 1i e r head Figure 13 o Remove cl fi Le nec .

and nut to left cylinder (F u r e 23. 145 Ins to 25-35 146 Insta to 25-35 1 cylinder i t. and 152. Instal gaskets Fu c 23. ighten and .).0 y to warm air screws (Figure ate with screws 24. Ass attach switch to 8Ib -in nipple 0-30.NOTE t n all bolts 143. 150. I sing with c f Ins I sover pi depress r valve hose to oil 15I. 149. ti T hten bracket 148. re ine coolant pi on e ine with new head.).

0-1. RTV sealer to end of warm air heater and insta 1 aptor assembly ith existi screws and washers re 24. (1. 153.Figure 24. 2. outlet cure with c (Figure 25 ).). Tig en to 8lb. ly . a t ch t s bo tom outlet a into mounting bracket 3..6 ). Nm).n .

in mounting b ckets making s re that there'is clearance between er a fender skirt between ter and 156 mount mounting 5•) brackets s

t to

e 158. Usi two cl pi Tighten cl
f

7

install

7

95

Figure 159 Connect ater control diverter ass y wi and low EGR valve cannis 160. Route at between fender diverter sw tch 1 1. Secure wire rness to batte

26.
on air

nut r. a

cables

wi

i

re

)

.

162. Connec black wire r bus b rs (Figure 27.)

e 38

F

ure 27.

IN

s st s inside battery box

166.
(F

Ins

r

3

( 4 • 0 - 6 • 0 Nm) ,

2

5 in ition on o. place F gure seal ). (20. tte bracket and place b Torque to 40-60 lb. Remove nuts on holes and reins a F ure 28 ).0 28 168.0 Nm). (4. Place fro ba seal.0-27. in . Reinstal bolts in fuel filter bracket Tighten to 15 20 lb.-in.ft. 171. Tig .-ft. 169. in positi f i verter .e 39 167. ( and secure to firewall. 1 te ts.

10first ith . in (8 0.1 .11 .0 Nm).9 5 lb. 176 Insta filte (Fi 177.S lb 175 (14 Ti 2 ten f 0 ) box is ali ed screws bracke screws from "T" to 15-20 it connec connector. . and tigh en -in.e 0 172 diver 173. T i g h ten to 70.). 178. 2 . 17 I sta to 70. to fuel Nm) . Tighten to 10 Inst and wi s rt bracket u tte cable to fender and Secure in place 28 •). Install ghten er and install from filter to heater rt bracket to right nner fender (Figure 28. Remove pI (F re 30.

(8.). Tighten stud 1 ne c p around el 70-95 lb.e 181.0 182. Install rear batte battery box. Connect s rt cI (Figure 30. e and Install fuel ) Tighten r 1 to wi .-in.

in clip and secure 184 ckets. 0 5 7.-in. mo ure 32 ).) coolant 1b •. lockwashe s and clamps ighten nuts to 40 60 lb. 0 Nm).e 42 NOTE s 183 Install T ghten to 18 lines is not Ml 10 (F ure 31. 184 to furnace mounting 185.i . (. Instal brackets wa rs (F .) T in step nuts. items assembled 32.

-in.) er 2 . linkage and 86.-in (8 5 1 a Nm). (1 0-2 0 Nm • f E S 188. and secure to oil w th c1 Pi ure 34. ta i Secure bolt ter exhaust igure 34. pi T with n 0-180 cl nut and se1flb.e 43 P 2. 187. nd ( Sec ure . 1 8 is for 1009 only.) Tighten to 7 95 lb.). Install coolant heater exhaust pi under steeri n outlet between eng ne and frame at cutout.

3-3. Tighten .-in to n i les wi (2.4 Nmi c e to to Ins u of ea 11 e 35. T h n to to coolant crossover ou let and into ace (Fi re 35. Ii ass lies to cool nt a te r c NOTE ne all 193 (F installi sove 3-30 lb. el a u 33.).).Ib -in nto cl ( 8 5-11.0 plac cl Reinstall Tg t e st into cover on ater ta t n 19 s 3 11 se ) ass ly to xve F 19 .

.e 45 Figure 34.

Install clip coolant se. a secure with nut a re 35. and enla e F 196.ex 195. . Remove ti 1 ist to clip on i F of La t or s ur e 35.).). ter iator overflow t (F r e 35.

0 es existi Nm).).' lb.0 Nm). Install cl on ket. attach to generator mounti It (F 36.).0-50. 198 s to 15-2 010 on . (36.0-27. Tighten 197.-ft. ssor wi existi (20.P e 47 M1010 F re 36.-ft. secure wi 26-37 lb. to NOT s 198~ At c (F ure36. bolt .

1 fuel line from 1 15-20 Ib.0 200.-ft. fuel ly (F ure 38 ). Cl p 1 line to heater mount.0 Nm). Tighten to 15-20 lb. F 201. Install connector on inlet side of coolant ater a install 1 line wi flex e from fuel filter to coolant he ter F ure 37. . Connect swit ass ure 37. (20 0 27. and secure to fuel lines w .).-ft (20.0-27. and str coolant e ctrical harness to heater.

.Figure 2 2. It 03 Secure nut and It he F 38. with ) . ft. (20 0to lower ho in rear Ti hten to 5-22 ft. . nut Nm) • s to rear batte box with hten to 15 22 lb.

1 .F 39. .

0-30. ater t (F tte n to 1 2 lb.0 Nm). M1010 Figure 40. Secure t wi n t and 20.-ft.-ft. pI in e 207. . install toward e ine tment (F ure 39.).e 51 NOTE S 5 206 are to (F 010 in rear T 5. e to front two 40. From underneath right inner fe r.0-30.0 Nm • 206. Tighten s in rear tte to 15-22 lb.). Secure 1 ater lower Ie wi nut (20.

t e junction r ts in .208 209. k Place ies i wi 1 s.

. ( .e abIes to r skir in. (4. drilled hole 1. ter Ie fitting. ns u s to ry hold in. ater fuel e ect ical connector c fuel ine ne on heater. va s a er cover.5-7 rs ure 41 •• ten 3 covee i il sion t p il to p r level. 1 vel e i e s c eaner bl 1 a f 1 tern of stem s air -0 ter. i ..

.

5 Figure NOTE 42. oil . ck fuel. Re to aux 1 label to i coolant 236.

5 L HOSE HaS!? PAN LT 336 14063337 14 730 14 72 00 14072400 14074 04 1 07 39 140744 XXX XXXX X X x XX X X X S L 140 683 a 1407 1407239 14074403 1407440 1407239 1407 403 14074404 1407239 14 7 403 1407440 14072394 14074403 14 744 3 1407 40 072394 14074403 14072398 14072397 14072399 1407440 14072397 14072398 14074404 4072391 14072397 14072398 14074 1407440 14072394 14 3 14072397 98 X F x 16 9439930 X 9201 x X x X x PI E I EXH 15599200 XX XX X X X X X PIPE CLAMP EXH 15 15 215 9217 X X XX X X xXX XX BaLT- a 1 x 4 316 1 99921 x X X X CLIP 275 x X XX X .

P REINF HD -20 x . 14072392 0 1 0723 2 XX X X XXXX XXXX XXXX XXXX XXXX XXXX XX X X LIST HEATERS (conti NO.50 XXXX XXXX XX X ASM-HTR SCREW-HEX HD WA 1 -20 x 9437 .5 x 12. X XX XX X X X XX XX X X XX XX X X BOLT-HEX HD 4-20 x 1 9440320 X X NUT 1/4-20 9422273 X X X PIPE ASM-ENG PIPE ASM-ENG PIPE ASM-WM PIPE ASM-WM PIPE ASM-WM WIRE ASM-BLO BLOWER NUT-HEX COOL HTR RR EXH HTR RR EXH AIR HTR RR EXH AIR HTR RR EXH AIR HTR RR EXH AIR INL RES AIR INL 14074499 15599212 15599 2 15599211 15599290 14076237 14074465 9419143 15500190 14072415 9440926 140762 ASM-HTR 1 -20 WASHER-LOCK BRACKETSCREW-PAN 6.e 57 PARTS ITEM CLAMP ASM 14074487 14074404 14072394 14 4403 14072 97 14072398 14072399 14074404 14072 4 14074403 14072397 14072398 14072399 14074 4 14072 4 14074 3 14072397 14072398 14 2399 14072394 14074404 14072397 14072398 140723 14072392 14072393 14072392 14074402 14072392 14074402 14072392 14072392 .

e 58 2 S 1 23 XXX X XX X 1407 78 91 1 072392 1 0723 FF 15 5 2835 70 11503 78 40 36 14 7239 14072 140723 2 1407239 14072392 72 92 X X XXX X X XX XX XXX X X XX X X X CLAMP 3/4 FL 89 6 1 0723 2 2392 9 23 14072392 14072396 9 08 5 352 20 . EL 1. x 370 12 2347 14072396 14072396 XXX XX X XXX X XXXX XXX XXX NUT BOLT-H 1 - 0 510 749 14 7239 14072396 1407239 9440173 4 8 072395 47 2 4402 .

59 S LIST -

SPACER JACKNUT CONNECTOR 10-24

74 15599231

XXXX
X X X

14074402 373 9440927

XXX

FILTER-FUEL - EX 10 24 x 2.25

XXX XXX X 1 072 1407239 1 7 XXX XXX X X

T E-THREE P PE LP P ST CLIP

WAY L WARM R HTR

118806 14072371 3444

ASM-FUEL

R

FD

1

369
6

1 07 10
1 07239

XXX XX XXX XX 96 X XX XXX XX

1 HOSE ECTOR L FE D 1

512 072368 200 49

0723 1 07

P R INL FRT R E-HTR C
I

14072396 1 2391 72391 4074 06 46

1 075856 356128

E L RR

X X X XXXX

ASM-HTR

074410

61 PARTS ITEM PART ET-TH ELBOW-HOSE HEAT ADAPTOR SCREW VALVE SWITCH 8x
NO"

LIST - ENGINE

HEAT

ti

14028916 90° 327 4468 R 16 AIR DVTR DVTR
x 1

14 14 14 2

01

XXXX

5

X

XX

14074466
2

2395 14

XXX XXXX X

ASM-WM ASM-WM

4473 9972 3550 4474 140 4413 140 10 93 140 1 5 3

SCREW-HEX

HD TP 4

XXXX XX X

HOSE ASM-HTR CLAMP HOSE PIPE AIR

L ADPT

XXXX XXXX X X

BLO FRT EXH

4475 15599287

STRAP GROMMET NUT-PUSH BOX SUPPORTSUPPORTBOX RR EX FLG 1/4-20
1

1906 15599925 32 1 00 76241 6249 76250 76243 915

14 7 392 140 392

XXXX XXXX

XX
1 1

X

5 23

XXXX XXXX X XX X XX XX

14072385

94

PIPE

FUEL

HTR

2378

14

25 9 0034 5 99236 59 928 1 07 1 7 7 XXXX XX XX 1 CLT HTR 10 372 1407 .e 2 4476 R 99203 14 7 140723 1 072 1 072 5 5 5 5 X X XX X X X XX XXX XXX XX XXX XX XX 1 074412 1 074477 815 14074459 1407 458 5599233 1 7 457 4460 LT E HTR HTR Q 1 07 3 5 1 074402 14074 0 7 1 07 1 07 1 07 1 3370 838094 5 9 240 1 0744 1 74 1 1 XX X X X XX 1 X 1559923 130 9611 1 07 10 1 I R THERMO NG HTR HTR SCKT PLUG 15599241 15599238 15599237 1 06 373 1 07 1 07 1 7 XX XXX XXX 01 01 0 XX X X X H -16 x .

e6 L 4 E BOLT-HEX ER INLT CLIP-HT PIPE HaS L FRT EXH 1 CLT 18 x 1 1 1 234 1 283 9 444 809 99243 140 140 06 6 140 140 1 X 9245 X HOLD 2 COVER ASMBAT DOWN 1 76852 86 X 1 76246 2039294 2 ING INSTR 1 1 08 61 9246 140723 X ENG IL LER LT-HEX 0-1.5 x 65 02892 GROMMET-HT 45° CL PGASKET L CaNT LARE LI LARE 34 225 761 15 1 07 1 07 5° 9409754 .

.

to 15-22 1 1 4.'. mount 2. . tire.e 65 II. j ack rae • in insulators t Remove seat. mount Remove eommunieat h t. 3. 1.. Loosely stri s i ." F ure 1.

). Hand mounti bracket ten to 5-140 lb. (F 1 under Ti ins ator ass ts to f 1 s in in it ill ur e 2. wi 1 brae NOTE r rear Usi ator s in 1 se . ) ns a mounti ts (3 on 1 s ) install new ).-in.66 Install 3.

.ure i f 1 lace ei la s ar si h i d . 1 .

-ft. at front of c as a in nut.). install n to 4 70 Ib -in. 1 .e6 SEALER 14 Install es (F t ) was r in f 1 center as T hte i drilled 5-22 lb. Tig area ill two (F remove s 1 insulator install 1 re 5. n install Remove ast c from plastic ure •)• mo nut. 32 i It.

ure 5. ril 5•) • s h ns la into .

. ion sea a 14 7.e7 F 6.1 . Remove 1 Ins to 10-15 Ib -ft. i . T ts F 7.

NOTE te rear seat la i 26.-in.0 Nm).0 Nm). Install re loor F re 6 30-45 lb. F 5.0-30. Tighten Nm) • next to to .-ft. insu tor Install jack a 9•) • .5-7.1 . ( . tall j k Ie mounting acket to Its to 40-70 lb. 23. ure 8 on rear seat with bolts.-ft. 24.0 60. ly rs and new (20. (F Remove Remove Install 8•) • Its from rear seat rear seat lat ss Its. ft.P e 71 22.. Ti to ensure correct t o ly in vehicle and inse t s e new 1 er bolt with washer. ( 0. Tighten t Install Its in rear seat belts 30-45 lb.0 Nm ) • er Its teel atch ass y with two Tighten bolts to 15-22 lb. ( 27.

J .2 F 2 Ins 0b Figure 1 ure 9. t ac I re tire e to and t r F ure 10.

30.). communications . ly new jacki Install is to 1 instruction rack. label on tailgate (F ure 10.l' NOTE e 73 T area re 1 clean and smoo 29.

74 ) I IN INSU ASM- L R RH 140 3341 1406 34 140633 1406335 6 1 723 X X X X X X X 1 072 OTR RH FLR WD 8-1 -16 x 2 INSUL 1 072 140 1 723 (15 9 14 72 (1 59 1 ( ox 3 129394 6262213 944018 140 3 8 SE LH 1293 7 1 063 7 9 7 5 X BRAC SC F IDE HD WD 8 INSU 1 ( 1 ( X 1 72 X X INSU ASM-SIDE PNL RH 14 633 4 140633 2 3 14072 14072 88 INSULATOR-SIDE BOLTHD PNL LH 16-18 x 1- 15599281 X IDE PNL INSUL WASHER-FL NUT-LK 16 x 1 16-18 PNL FRT 10 x 2 1 0633 2 3790662 9422275 14063351 129642 3866846 1 0723 (15599 0 14072388 (1559990 14072 8 (1559 9 14072388 14072388 4) (15599 14072388 (15599904) X X X X X X X X X X INSULATOR-FLR LR HD WD NUT-20 X 1 .

} (conti 126341 9419105 14063352 14063359 14063353 14072388 ( 5599904) 14072388 (15599905) 14072388 (15599905) 14072388 (15599 05) (1 X X X X X 2-13 x 2 ST EAT-PROP ST HD 16 -20 x HOLDN X X X X X 072 8 59 905) SCREW ASM-HEX 16.8 x 1D1 3992648 9419004 14063360 14063358 14072450 143471 9981403 140 2388 (15599905) 1 072388 ( 55 9905) 8 X X X X 905) 1 72 88 (155 905) 1 0723 8 ( 599 05) 14072388 ( 407 407) 1 0 2392 X X X X SPAC SPA TIRE MTG USAGE LABEL-JK WASHER SEALER X X X XXXX ..e 75 INSULATOR DESeRI BOLT-RD BOLT-HEX SPACER-RR ROD S ER-RR HD 1 -20 x 1PART 0 NO .

0 Nm). ts 1 screws Install retainer rs on cover a fasten into it 1..-in (2. (F jac . 6. to wi install 1 1 mar sealer 2 inch diameter in drilled es (F ure 1.III 1. Ti ten screws to 22-27 lb. 3. .).0 Nm) wi screws . center r jacknuts 5 maintaini r to cove 1 i. start (2. letteri over and cover NOTE Do not overt will screws to 2 screws. .-in. of cab. INSTALL Remove ILTED Its from antenna ate 'are printed 9 mount remove mount. mark lese 2 ine (Instructions f on rear 1a te •) NOTE ant Drill 4.. or j 3.).

Reta ni will be er .P 77 Figure 7• cover cove 2. over rear of vehic 1.

stra ht ( F ure 3 • ) • s on right and in les ( F ure 3 ) while ft si keepi s of o. (14. NOTE cover t Center cover over rear of vehicle. 12. Center icle ( F ure 3 • ) • drill 1 32 inch jacknuts 11. Mark les h center metal inserts in cover alined v of les in sides of cover. NOTE Do not 11 Looseness of i Smoo out on 9.-in.0 Nm) .0-19. (F ly sealer install . Its Install antenna mounti ate ure 3 • ) • hten lts to 124-168 h les in cover wi lb.F re 2.

PLACES SHOWN-R. in place Nm).) TYPICAl. OPPOSITE I. 15. Center Figure 4. (F Insta 1· cover ure 4 ). W/ANTENNA MOUNTING PLATE (OPTIONAl.H.5-3.H. ly sea 32 i les on r left sides ure 4. tall jacknuts: in drilled 16. (2. left sides th h cover ht holes (F ass Ma two ate area les on r ht (F ure 4. T jacknuts and secure cover to 22-27 lb. drill r 1 1y at 14.).-in.. F 13. tai ure 3.).0 .).79 AS A TEMPLATE MUST BE IN A STRAIGHT LINE.

.

.

te i suI tor and drill and ins all jacknuts into jacknuts 15/32 inch diamete holes ai les al te F i ure 1 sealer in drilled in tai ate 29 30. Iy seale nst 11 Install nsta I jacknuts ributtons i to jacknuts in drilled 3• 36. . 3 2 I st 1 Instal Mar Remove turnb ttons tailg es in tai te insulator ttom of tai te insulator NOTE ate insulat in grommet ngs. o 2 Remov tailg 6.).insulator nsulator at a t a while ke pi rna k tailg es in te in ula ION is of rolled 7. ta 19ate ins lator over tu ttons and secure in place. i knesses f me be i 33 3 Center and drill 1 32 inch diameter holes holes in ailgate.

123 COVER ASM-ROOF ASM 4-20 x COVER 8 14075881 9440210 14075884 14075883 367292 E 4075882 14063367 4-20 COVER 2711 2 1559 903 9981403 40723 3 X X X X X X X X X X X X X XXXX SCREW-WA 1 072 3 ( 559 906) 14072383 140723 3 RETAINER-ROOF RET NER-ROOF NUT-JACK COVER 4-20 14072383 (15599906) 407 383 1 072383 15599906) 4072383 155 9906) 4072383 1 072400 ASM-TAI TURNBUTTON NUT-LK TEMPLATE-ROOF SEALER .e PARTS ) 3 KIT NO.

2 Remove Remove Remove ure 1. brae 3 (F Ret to f of iele RT FLO R F ure 1. Its trans i front seats to floor remove sea s zel and boot assembly. 1.IV. ) . . i NBC mounti t (F re 1.

and ~S 6 is i 09.s 5• s from ce il a a r"emove. s. box at r. remove and sca t insula . Its. e 7 from sho Ie jac er belt retractor nd 1 wrench from Remove 9 floor n t.

icl t .NOTE a P ace two ) i suI tors on floor of veh c e F ures 2 NOTE s 1 PI 1 o sealer NOT ( on s s wi MIOO 1 2) 1 s i o of i mats place on each s F ure 3 ).

87 M1008.1 . . 1'028 &: 1031 (SHOWN) 031 F ure 3.

lb. . (26 0-40. T T hten h n o 45 lb. oam wre u ators.-ft. wit 4 Tighten Tighten 4 Nm ) • 17.. 19.0 Nrn).. j k ove in rnounti s S 15 15 not It retrac to 3 to floor. F e 3a. 1 14.-ft. s .60 . I I I s.0 Nrn).0. 18..

e 89 PARTS LIST-CAB NO. 34 X X INSULATOR-FLR INSULATOR-FLR MAT-FLR EXT RH PNL FRT PNL RR 14076802 14075863 14076810 1 072387 14 72386 14072 87 1407 386 14072 9 1 072 86 1407 3 9 1 1 XX XX XX X INSULATOR-FLR INSULATOR-FLR MAT-FLR EXT LH PNL RR PNL RR 14075862 14075864 14076809 X XX X X 072 6 o 2389 INSULATOR-FLR SEALER PNL FRT 14076803 9981403 o 2 9 0 X 14072 .

/ o c s .

e .

2 f .

3 Fi i ure .

.

. . c h tch 1 s 10. d mov c r pia s n a k on tions E 1o r fi in s a t .).U r n a re mol 1. ft s a et 8 nd Remove ei sta lug te s from te side stalling in ri t sition and three ckets and r seat assembly ack. side ening. 3• 4 INSTALL r Pull i ga r ta E CARGO 1 up iet Remove Li ide Remove r Ig t ai and 0 aps on i f ate. 2. ht out. rom ne two r ue Ii s.. k s Ion a or moldi 1 / n 11 h -c i r 1 i. e.

f t ce f f 7 il ho ) t (F Figure 1 .

L ie ront. and wheel 1 insulators rs as 2 •) • into box s on wheelwell ide in ul rs (F ac s E drill 3/32 0 Secur is ns s on s r r out of r k en r f as 2 .sition e 2.1 .

s la or r r t .NOTE on of floor panel of pi up bed (Fi u e 3.) ding.

99 f / 1 "" .

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