DESIGN ENGINEERING 901061 Commander Max Heat Control Kit Installation Guide

DESIGN ENGINEERING 901061 Commander Max Heat Control Kit Installation Guide

INSTALLATION INSTRUCTIONS

PART #901061
16 Pieces dimpled aluminum/glass fiber custom cut shields
1 – Glass Fiber Exhaust Wrap Material
6 – Exhaust Wrap Clamps
1 – Heat Shroud Line Sleeve
1 – Roll Cool Tape

NOTES

SURFACE PREP:
Vacuum or wipe down installation area to remove all loose debris/dust. Then clean with propyl alcohol to remove any contaminants.

Park on level ground and block wheels for safety

TOOLS:
Use manufacturer’s suggested tools for panel removal.

Cleaner/Degreaser, Cloth, Side Cutters.

Drill with 1/2” bit

Torx T25 bit

Optional panel pin removal tool or flat blade screw driver

**Diagram of pre-cut shield pieces

Cool Tape

Exhaust Wrap Material

Exhaust Wrap Clamps

Heat Shroud Line Sleeve

**

STEP 1 . Remove all 4 seats
STEP 2 Lift the lid on the rear console and remove the push pins and then lift out the condole. **(Fig 1)

Fig. 1 – Remove push pins from entire perimeter of console. You can use tool as shown to the right, or a flat head screw driver to pop up the center of the push pin, then pull it out of the hole
Alternate speciality tool to remove pins

STEP 3. Remove the T25 Torx screws from the 3 grab handles and slide the rubber grips up and off. ( Fig 2)

Fig. 2 – Remove Torx screws from handles and slide rubber grips up and off
STEP 4. Remove the shift knob by loosening the jam nut and unscrewing the knob (Fig   3)

Fig. 3 – Loosen jam nut (red arrow pointing at jam nut) adn unscrew shiftier knob
STEP 5. Remove the center dash section held on by 2 T25 torx and push pins. (Fig. 4)

NOTE : Note which torx are removed from the various locations during the install as the lengths are different.
Fig. 4 – Remove Torx screws from top of center dash
STEP 6. Open the glove box door and lift the center dash back and up. You should be able to set this on top of the dash with the wiring connected. (Fig 5)

Fig. 5 – Open glove box door, lift center console back and up. Set on dash with wiring connected.
STEP 7. Remove the main console fasteners – push pins and 2 T25 torx on the left side. Lift up slightly on the drivers side and unplug the override switch. (Fig 6, Fig 7, Fig 8)

Fig. 6 – Remove main console fasteners on driver side and lift up to unplug override switch

Fig. 7 – Lift up slightly and unplug Override switch

Fig. 8 – Override switch
STEP 8. Remove the remaining fasteners from the center console. (Fig 9)

Fig. 9 – Remove remaining center console fasteners
STEP 9. Now the console can be removed by lifting up and ahead to clear the grab handle bars. (Fig 10)

Fig. 10 – Remove center console by lifting up and ahead to clear grab handle bars
STEP 10. On the drivers side rear floor remove the 4 push pins and the floor piece ( Fig 11)

Fig. 11 – Remove rear driver side floor piece
STEP 11. Remove 4 push pins and the lower rear center console panel. Driver side. (Fig 12)

Fig. 12 – Remove rear center consol side panel
STEP 12. On the passengers side rear remove the 4 push pins and the lower center panel. (The piece with the oil fill opening in it.) Fig 13

Fig. 13 – Remove passenger side rear center console trim. (Piece with oil fill opening in it)
STEP 13. Remove the rear drivers side floor panel which is held on by 4 bolts and a push pin. (Fig 14)

Fig. 14 – Remove rear driver side floor panel
STEP 14. Remove the CVT air elbow held on place with 2 hose clamps. (Fig 15)

Fig. 15 – Remove CVT air elbow
STEP 15.** The exhaust wrap will cover the front head pipe where it runs under the floor. Wrap the material around the pipe and attach with the speed clips.

Fig. 16 – Wrap exhaust wrap material around front header pipe and secure with provided speed clamps

NOTE: To install speed clamps, pinch material edges together and insert both edges in to speed clamp.
Then press two sides of clamp closed together with pliers. **Fig 17

Fig. 17 – Installing speed clamps
STEP 16. Remove the plastic split tubing from the coolant return line and attach the Heat Shroud around the line with Velcro. Replace the plastic split tube. (Fig 18)

Fig. 18 – Peel back plastic tubing on coolant line and install Heat Shroud reflective sleeve
**

INSTALLING THE PRE-CUT INSULATION:

NOTE: For proper installation and long life of the kit, the inside of these metal panels will need to be clean. Wash the panels with soap and water and dry thoroughly. Then wipe the inside of the panels with denatured alcohol or window cleaner and allow to dry.

NOTE : The adhesive is very aggressive and the insulation cannot be adjust after it is applied.
When you have the part matched up remove a small amount of the backing sheet and apply the insulation to the panel. Then pull more of the backing sheet away and work your way across the panel attaching the insulation.

The pieces are grouped an labeled so they are installed on the same piece. Example both 1A and 1B are installed on to the same panel.

Install 1A and 1 B on the under side of the center console. 1A installs on the bottom of the cup holders. 1B installs in front of the cup holders and presses down into the cavity.

Install 2A on the under side of the front piece of the center console. This is the storage area under the front part of the center console.

Install 3A, 3B, 3C & 3D on the back side of the piece that goes on the drivers side of the center console.

Install 4A, 4B & 4C on the under side of the driver side rear seat footwell piece that goes on the side of the center console

Install 5A, 5B, 5C, 5d & 5E on the under side of the piece that goes in the rear passenger side of the center console. This piece has the Oil fill cap coming through it.

Install 6A on the underside of the rear driver side floor panel

STEP 17 Cover seams where heat barrier material butt up next to each other with supplied reflective Cool Tape. Fig 19 & Fig 20.
NOTE : Making small relief cuts in the Cool Tape will help go around bends and curves **. Fig 21

Fig. 19 Seal seams with supplied Cool Tape
Fig. 20 Seal seams with supplied Cool Tape

Fig. 21 making small relief cuts helps when installing Cool Tape around bends and curves
**

REINSTALL PANELS

STEP 18. Install the drivers side rear center panel and cvt cover panel.
STEP 19. Install the side panel on the passenger side rear. The piece with the oil fill hole in it.
STEP 20. Install the rear driver side, side console piece
STEP 21. Install the rear driver side lower center console piece
STEP 22. Install the main console. With the rear of the console elevated you will be able to line up the front and lower the console down over the the grab handles
STEP 23. Plug in the override switch wiring harness.
STEP 24. Install the push pins and two torx bolts to secure.
STEP 25. Install the 3 grab handle grips and the torx bolts
STEP 26. Reinstall the shift knob and tighten the jam nut.
STEP 27. Install the rear console with push pins.
STEP 28. Install the center dash.

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