1. | See Figure 1. From the back, remove the three screws. |
Figure 1. Rear Screws | ||||||||||
2. | See Figure 2. From the front, remove the screws, block-off panel and glove box. Disconnect the vent door linkage. |
Figure 2. Locking Tab and Block-off Panel | ||||||||||
3. | See Figure 3. Remove the three glove box screws and the glove box. |
Figure 3. Glove Box Screws | ||||||||||
4. | See Figure 4. Remove the screw and the linkage. Install on the new enclosure front. Tighten the screw to 1.3–2 N·m (12–18 in-lbs). |
Figure 4. Vent Linkage Screw | ||||||||||
5. | See Figure 5. Clean the area with a mixture of 50-70 percent isopropyl alcohol and 30-50 percent distilled water. NOTE To ease assembly, install and remove the screws (6) in the enclosure without the tray first. | Figure 5. Gasket Mating Surface of Lower Fairing | ||||||||||
6. | See Figure 6. Assemble the front enclosure and the enclosure tray and install the two self tapping screws (6). Clean the edge of the tray flange where the foam gasket is to mount with a mixture of 50-70 percent isopropyl alcohol and 30-50 percent distilled water. Remove the protective seal from one side of the double sided foam gasket and install the foam gasket as shown. Trim and save excess foam gasket, it will be used later. |
Figure 6. Enclosure Assembly | ||||||||||
7. | See Figure 7. Position the enclosure assembly and connect the linkage. | Figure 7. Connect Linkage | ||||||||||
8. | Remove the seal from the foam gasket before assembling the enclosure sub-assembly. Position the enclosure assembly. | |||||||||||
9. | See Figure 8. From the rear, install the three self tapping enclosure screws (9). Tighten the screws to 1.3–2 N·m (12–18 in-lbs). |
Figure 8. Rear Screws | ||||||||||
10. | See Figure 9. Fold a piece of trimmed gasket over the locating tab of the block-off panel and install the panel. Apply a drops of Loctite 242-Blue to the threads of the screws. Install the screws and tighten to 7.3–8.4 N·m (65–75 in-lbs). |
Figure 9. Block-off Panel and Locating Tab Foam | ||||||||||
11. | See Figure 10. On the back side of the glove box, measure about 25 mm (1.0 in) over and 9.5 mm (⅜ in) up from the lower fairing cap mating flange. Mark the location to drill the hole. Cover the drill point with masking tape to prevent cracking or chipping of the paint and drill a 9.5 mm (⅜ in) hole in the glove box inboard side wall. Insert a rubber grommet. | Figure 10. Drill Location | ||||||||||
12. | See Figure 11. Insert the four well nuts. NOTE If an amplifier is used, fairing lower speakers are connected to the front amp [313]. This includes 4, 6 or 8 speaker configurations. If an amplifier is not used, fairing lower speakers will always be connected to the stock harness connector [162]. | Figure 11. Well Nuts | ||||||||||
13. | See Figure 12. Route the wiring harness under the fairing up to the radio and connect to either [162] (without fairing amp) or [313] (with fairing amp). |
Figure 12. Harness Connection | ||||||||||
14. | See the service manual, install the lower fairing, leaving the lower fairing cap off. | |||||||||||
15. | Route the speaker wires through the hole in the lower fairing. Light Blue & Light Blue/Black wires to RH side. Light Blue/Orange & Light Blue/Gray to the LH side. Secure wire harness with cable straps and verify wiring does not interfere with steering or suspension travel. | |||||||||||
16. | Install the lower fairing cap. | |||||||||||
17. | See Figure 13. Connect the speaker wires. Position the speaker so the tweeter is in the top outboard position. Install the speaker cover with the Bar and Shield positioned correctly and install the four screws. Tighten the screws to 0.3 N·m (3 in-lbs). | |||||||||||
18. | The wire harness included in the kit has a reference tag attached. Check the box marked "LOWER SPKRS" for future reference in installs/upgrades. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Screw, #6-32 PAN HD, TORX, Black (8) | 10200105 |
2 | Grille assembly, 6 1/2" premium (2) | 76000324 |
3 | Wire harness (1) | 69200612 |
4 | Woofer assembly, premium, 6 1/2" (2) | 76000320 |
5 | Welnut, #6-3 (8) | 5210 |
6 | Screw, self-tapping, 1/4" X .75" (4) | Not sold separately |
7 | Speaker enclosure, tray, fairing LWR, RH (1) Speaker enclosure, tray, fairing LWR, LH (1) | 76000369 76000368 |
8 | Gasket seal (2) | Not sold separately |
9 | Screw, #10 self tapping (6) | 2995 |
10 | Grommet, harness seal (2) | 11410 |
Items mentioned in
text, but not included in kit: | ||
A | Lower fairing | |
B | Front enclosure |