Heater Kit

P/N 2884735

1 Before You Begin

Read these instructions and check to be sure all parts and tools are accounted for. Please retain these installation instructions for future reference and parts ordering information.

3 Kit Contents

Ref

Qty

Part Description

P/N Available Separately

Available Service Kit

1 1 Bracket–Heater, Front n/a n/a
2 1 Bracket–Heater, Left-Hand n/a n/a
3 1 Bracket–Heater, Right-Hand n/a n/a
4 1 Adapter–Duct, Demist n/a n/a
5 3 Screw–Hex Head Flange, Hi/Lo, (4.8 x 1.59 x 11 mm) n/a n/a
6 4 Rivet–Push, 1/4 in n/a 2208877
7 6 Screw–Hex Head Flange, (M6 x 1.0 x 20 mm) n/a n/a
8 8 Screw–Hex Head Flange, Hi/Lo, (4.8 x 1.59 x 15 mm) n/a n/a
9 1 Assembly–Heater 2415876 n/a
10 1 Assembly–Mode Control 2415877 n/a
11 1 Assembly–Electronic Temp Control 2415878 n/a
12 1 Harness–Heater (not shown) 2415879 n/a
13 1 Assembly–Control Panel 2415880 n/a
14 1 Assembly–Inlet Hose n/a 2638301
15 1 Assembly–Outlet Hose n/a 2638301
16 2 Hose–Flex 2638302 n/a
17 2 Grille–Vented n/a 2638303
18 2 Inlet–Vent n/a 2638303
19 4 Screw–Pan Head, #8 x 1/2 in n/a 2638303
20 1 Assembly–Floor Vent n/a 2638304
21 2 Screw–Hex Head Flange, (M6 x 1.0 x 12 mm) n/a 2638304
22 10 Cable Tie (not shown) n/a 2208877
23 2 Clamp–Hose, (23 mm) n/a 2208877
24 2 Clamp–Hose, (37 mm) n/a 2208877
25 1 Clamp–P, 1-1/4 in (not shown) n/a 2208877
26 2 Rivet–Push-Pin, (8 mm) n/a 2208877
27 4 Nut–U n/a n/a
— 1 Heater Kit Templates 9939926 n/a

4 Tools Required

  • Safety Glasses

  • Cutting Tool

  • Deburring Tool

  • Drain Pan

  • Drill

  • Drill Bit:

    • 5/16 in

    • 5/8 in

    • 1/4 in

  • Hole Saw:

    • 1-3/8 in

  • Pliers, Hose Pinch-Off

  • Pliers, Push Pin Rivet

  • Scissors

  • Service Manual

  • Socket Set, Metric

  • Socket Set, Torx® Bit

  • Torque Wrench

  • Wrench Set, Metric

5 Consumables Required

  • Antifreeze, POLARIS 50/50 Premix, 2-4 quarts

  • Cleaning Solution (99% water + 1% mild dishwashing detergent)

  • Isopropyl Alcohol (IPA)

  • Gloves, Chemical Resistant

  • Silicone Lubricant

  • Solvent Wipe (99% Isopropyl Alcohol)

6 Important

Your is exclusively designed for your vehicle. Please read the installation instructions thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For your safety, and to ensure a satisfactory installation, perform all installation steps correctly in the sequence shown.

7 Installation Instructions

7.1 Vehicle Preparation

7.1.1 General

  1. Park vehicle on a flat surface.

  2. Shift vehicle into PARK.

  3. Turn key to OFF position and remove key.

Coolant Draining

  1. Refer to the Service Manual for procedures on draining the coolant.

7.1.2 Center Hood Panel Removal

  1. Turn quarter-turn fasteners to unlock hood from vehicle.

  2. Move hood forward to remove from vehicle.

7.1.3 Power Steering Cover Removal

  1. Remove two fasteners to remove power steering cover.

7.1.4 Dashboard Storage Removal

NOTICE
Storage bin shown; audio head unit bezel similar.

  1. Remove two push-pin rivets from top of storage compartment.

  2. Tilt storage compartment rearward to remove from dashboard.

7.1.5 Dashboard Top Removal

  1. Remove four dashboard fasteners.

  2. Lift dashboard upwards to remove from vehicle.

7.1.6 Passenger Dashboard Storage Removal

  1. Remove two push-pin rivets and remove passenger-side dashboard storage bin.

7.1.7 Passenger Hand Hold Removal

  1. Remove pin from receiver to remove passenger hand hold.

7.1.8 Front Dashboard Removal

  1. Disconnect the following:

    • Dashboard Switches

    • Ignition Switch

    • Console Lighting

    • Electrical Accessories

    • 12 v Charging Receptacle

  2. Remove two fasteners from top of front dashboard.

  3. Reach through opening and remove one fastener, connecting the bracket to the cross-beam.

7.1.9 Seat Removal

NOTICE
Driver seat shown; passenger seat similar.

  1. Reach between seat and backrest. Pull up on lever, located behind seat to disengage seat latch.

7.1.10 Center Console Removal

  1. Remove and keep four push-pin rivets.

  2. Remove and keep three console fasteners.

  3. Push shifter boot and seat belt boots into center console while lifting console upwards to remove.

  4. Remove center console from vehicle.

7.1.11 Close-Off Panel Removal

  1. Remove and keep two access panels.

  2. Remove and keep four fasteners holding the ECM to the close-off panel.

  3. Lift levers up to disengage connectors.

  4. Remove and keep four push-pin rivets.

  5. Remove and keep five close-off fasteners.

  6. Remove and keep four rear close-off fasteners.

  7. Lift upper close-off panel to remove lower close-off panel.

    TIP
    Upper close-off panel cannot be removed. Lifting panel only eases removal of lower panel.

7.2 Accessory Installation

Templates

NOTICE
Clean all surfaces, as needed, with cleaning solution or isopropyl alcohol before applying templates.
WARNING
Isopropyl alcohol is hazardous to your health. See isopropyl alcohol packaging for proper handling instructions, including recommended personal protective equipment such as goggles and chemical resistant gloves.
Vent 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.

Compartment Bottom Template

  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.

Compartment Top Template

  1. Apply template to outside of front dashboard panel.

  2. Cut along lines marked on template.

Heater Bracket Templates

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

  2. Drill three 5/16 in holes.

Firewall Template
IMPORTANT
Control tool depth. Ensure tool is clear of all other parts and components to prevent damage to vehicle.

  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

TIP
Harness connectors in this section only have one possible mating connector, except where noted.

  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)

7.3 Vehicle Reassembly

7.3.1 General

  1. Refer to the Service Manual for procedures on refilling the coolant and bleeding the coolant system.

  2. Turn vehicle on and operate heater system until the air output is warm/hot. Turn temperature control to cool the air output and let system run for a few minutes. Turn temperature control to warm the air output until cooling fan cycles.

  3. Verify coolant level.

7.3.2 Close-Off Panel Installation

  1. Lift upper close-off panel to put lower close-off panel in installed position.

  2. Install four close-off fasteners. Torque fasteners to specification.

    TORQUE

    Close-Off Fasteners:

    8 ft-lbs (11 N·m)

  3. Install five close-off fasteners. Torque fasteners to specification.

    TORQUE

    Close-Off Fasteners:

    8 ft-lbs (11 N·m)

  4. Install four push-pin rivets.

  5. Install two ECM connectors. Connector will lock when properly installed.

    IMPORTANT
    Make sure connectors are clean prior to installation.

  6. Install ECM to close-off panel with four retained fasteners. Torque fasteners until fully seated.

  7. Install two access panels.

7.3.3 Center Console Installation

  1. Put the center console in the vehicle.

  2. Install three console fasteners. Torque fasteners to specification

    TORQUE

    Console Fasteners:

    8 ft-lbs (11 N·m)

  3. Install four push-pin rivets.

  4. Pull shifter boot and seat belt buckle boots through center console openings and make sure they are properly seated.

7.3.4 Seat Installation

NOTICE
Driver seat shown; passenger seat similar.

  1. Put seat in installed position. Align latch with plunger on vehicle.

7.3.5 Passenger Hand Hold Installation

  1. Put passenger hand hold in receiver and install with pin.

7.3.6 Dashboard Storage Installation

NOTICE
Storage bin shown; audio head unit bezel similar.

  1. Install storage compartment with two push-pin rivets.

7.3.7 Center Hood Panel Installation

  1. Move hood rearward.

  2. Turn quarter-turn fasteners to lock hood to vehicle.

8 Instruction Feedback Form

A feedback form has been created for the installer to provide any comments, questions or concerns about the installation instructions. The form is viewable on mobile devices by scanning the QR code or by clicking HERE if viewing on a PC.