Accessory Installation

Templates

1. Apply templates to top dashboard panel, as shown.

2. Drill two 5/8 in holes for vent opening.

3. Cut remaining plastic between drilled holes within lines on template.

4. Drill two 1/4 in holes for fasteners.

1. Remove and discard storage compartment from front dashboard panel before continuing with compartment templates.

2. Apply template to outside of front dashboard panel.

3. Drill two 5/16 in holes.

1. Apply template to outside of front dashboard panel.

2. Cut along lines marked on template.

1. Apply templates to front dashboard panel, within storage compartment opening.

2. Drill three 5/16 in holes.

1. Apply template to front of firewall.

2. Drill three pilot holes according to the template.

3. Use a 1-3/8 in hole saw to cut three holes.

   TIP

   Access to each hole may be difficult. Access pilot hole from inside of vehicle, if needed.

Electronic Temperature Control Installation

1. Remove and keep two nuts from chassis cross-beam, located behind rear close-off panel.

   TIP

   Access from right-rear wheel well.
   

2. Install Electronic Temperature Control (ETC) assembly 11 with two retained nuts. Torque nuts to specification.

   TORQUE

   ETC Mounting Fasteners:

   22 ft-lbs (30 N·m)

   

3. Disconnect oil cooler hose.

   

4. Remove and discard oil cooler hose from water pump.

   

5. Install ETC hose (longer) to oil cooler with hose clamp 23.

   TORQUE

   Hose Clamp 23:

   30-50 in-lbs (3-6 N·m)

   

6. Install shorter hose from ETC assembly to water pump with hose clamp 23.

   TORQUE

   Hose Clamp 23:

   30-50 in-lbs (3-6 N·m)

   

Inlet Hose Installation

1. Put inlet hose 14 (longer) into hole closest to the driver’s side.

   

2. Make sure grommet is fully seated in hole.

   

3. Put inlet hose through drive line tunnel

   

4. Pull inlet hose 14 out of tunnel along shifter assembly.

   

5. Remove and keep one fastener from chassis.

   

6. Put P-clamp 25 around inlet hose and install to chassis with retained fastener.

   TORQUE

   P-Clamp Fastener:

   8 ft-lbs (11 N·m)

   

7. Put inlet hose 14 towards ETC assembly.

   

8. Verify O-ring is on fitting and apply silicone lube to O-ring before installing. Remove retaining clip from hose fitting. Install hose 14 to ETC assembly with the clip.

   

Outlet Hose Installation

1. Put outlet hose 15 (shorter) into hole closest to the passenger’s side.

   

2. Make sure grommet is fully seated in hole.

   

3. Identify coolant hose coming from radiator assembly. Cut hose in middle.

   

4. Install Y-pipe between two ends of coolant hose with clamps 24.

   TORQUE

   Hose Clamp 24:

   30-50 in-lbs (3-6 N·m)

   

Harness Installation

1. Install fuse relay of heater harness 12 onto firewall.

   

2. Install power connector into Polaris Pulse^® bar.

   

3. Put harness through drive line tunnel

   

4. Use cable ties 22 to install harness and hoses to vehicle components to avoid contact with moving parts.

5. Pull harness 12 out of tunnel and install along inlet hose with three cable ties 22, as shown.

   

6. Connect harness to ETC assembly. Use cable ties 22 to install harness and inlet hose to vehicle components to avoid contact with moving parts and heat sources.

   

Heater Assembly Installation

1. Twist flex hoses 16 onto duct.

   

2. Put heater assembly 9 into vehicle with bracket resting on chassis cross-beam.

   

3. Install bracket with two fasteners 7.

   Do not torque fasteners at this time.
   

4. Verify O-rings are on fittings and apply silicone lube to O-rings before installing. Remove retaining clips from inlet hose 14 and outlet hose 15. Install hoses with clips.

   

5. Put remaining harness connectors through third drilled hole. Make sure grommet on harness is fully seated in hole.

   

6. Install two connectors to fan speed module.

   

7. Put the mode control harness over the duct opening and install two connectors to the power harness.

   TIP

   Install connectors with matching dots.
   

8. Install heater assembly to power harness.

   TIP

   Install connectors with matching dots.
   

Front Dashboard Installation

1. Install top of front dashboard with two fasteners.

   

2. Torque two front dashboard fasteners to specification.

   TORQUE

   Dashboard Fasteners:

   97 in-lbs (11 N·m)

3. Connect the following:

   • Dashboard Switches

   • Ignition Switch

   • Console Lighting

   • Electrical Accessories

   • 12 v Charging Receptacle

Heater Assembly Installation Continued

1. Install right-hand heater bracket to front dashboard with two fasteners 7.

   

2. Install left-hand heater bracket to front dashboard with two fasteners 7.

   

3. Torque six heater bracket fasteners to specification.

   TORQUE

   Heater Bracket Fasteners 7:

   8 ft-lbs (11 N·m)

Floor Vent Installation

1. Align floor vent 20 with heater assembly and install with two push rivets 6 per side.

   

2. Install floor vent to front dashboard with two fasteners 21. Torque fasteners to specification.

   TORQUE

   Floor Vent Fasteners 21:

   8 ft-lbs (11 N·m)

   

Control Panel Installation

1. Align control panel 13 in front dashboard opening. Reach in from inside dashboard and install one push-pin rivet 26 on each side.

   

2. Install three control panel connectors to power harness.

   

Passenger Dashboard Storage Installation

1. Install dashboard storage bin with two push-pin rivets.

   

Demist Vent Installation

1. Twist flex hoses onto vent inlets 18.

   

2. Put top dashboard panel in vehicle.

   

3. Align dashboard with vent inlets and install vent grilles 17 with two fasteners 19 per vent. Torque fasteners until fully seated.

   

4. Install dashboard with four dashboard fasteners.

   TORQUE

   Dashboard Fasteners:

   8 ft-lbs (11 N·m)