Gator XUV-HPX Heater Installation (9PH20S30).pub

P. 1 of 12

p/n: IM-9PH20S30 Rev. R, 5/18/2015

JOHN DEERE GATOR HPX/XUV

2 PASSENGER HEATER INSTALLATION INSTRUCTIONS

(p/n: 9PH20S30)

Kit Contents:

5 6

Item: Qty: Description:

1 2 1” x 1” x 5/8” Tee Fitting

2 2 Plastic Snap-in Hose Grommet

3 4 1-1/2" Hose Clamps

4 10 1" Hose Clamps

5 1 2" Round Vent

6 1 Gasoline Sending Unit Adaptor

7 1 2" Vent Hose (4 feet)

8 2 5/8" Heater Hose (13 feet)

9 1 5/8" Heater Hose (10 inches)

10 1 1/4" Split Loom (2 feet)

11 15 Heavy Duty Cable Ties (11")

12 1 1" Flat Bulb Rubber (7 inches)

13 1 Edge Rubber (18 inches)

14 3 1/4-20 x 3/4" Flange Bolt

15 1 1/4 x 1" Fender Washer

16 3 1/4-20 Nylock Flange Nut

17 2 #10 x 3/4" Pan Head Self Drill Screw

18 4 #8 x 1/2" Flat Head Self Drill Screw

19 2 #8 x 3/4" Flat Head Sheet Metal Screw

20 3 16mm White Nylon Washer

21 1 5/8" x 5/8" x 5/8" Y-Adaptor

22 1 5/8" Flushing Tee / Bleeder Cap

23 1 5/8" Shut-off Valve

24 1 5/8" x 5/8" x 5/8" Tee Fitting

25 1 PSA Hook Velcro (96")

26 1 Glove Box Cover

27 1 Installation Instructions

28 1 Diesel Supply Nipple

29 1 Gasoline Supply Nipple

30 1 Heater Switch Assembly

31 1 2-1/2" to 2" Plastic Hose Reducer

32 1 Oval Defroster Vent Grill

33 1 Oval Defroster Vent

34 1 Vinyl Hood Seal Panel

35 1 Heater Hose Cover

36 1 Heater Assembly with Wire and Blower

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This manual is the property of the owner. Be sure to

leave with the owner when installation is complete.

Parking Safety

1. Stop machine on level surface

2. Set parking brake

3. Remove key

4. Wait for engine and all moving parts to stop before leaving

the vehicle.

CAUTION: Avoid Injury! Touching hot surfaces can burn skin.

The engine, components, and fluids will be hot if the engine has

been running. Allow engine to completely cool before servicing

or working near the engine or components.

1. Install Glove Box Cover

1.1 Remove the under hood storage compartment.

1.2 Remove and retain the (2) Phillips head screws on the inside

of the glove box. The plastic push-in clip retainer securing the

glove box to the fender can be discarded. Remove the glove box

and retain the (2) clip nuts from the glove box. Install the clip nuts

onto the dash board and install the supplied glove box cover using

the Phillips head hardware from the glove box. (See Fig. 1.2)

2. Install Heater

2.1 Connect the 2” vent hose to the plastic outlet on the front face

of the heater box and secure with a cable tie.

2.2 Move the heater into position and loosely bolt the bottom

right bracket through the hole in the vehicle fender with the

hardware listed below. (Note: the fender washer should be on the

underside of the fender. Leave finger tight)

Qty Hardware

1 1/4-20 x 3/4” Flange Bolt

1 1/4 x 1” Steel Fender Washer

1 1/4-20 Flanged Locknut

2.3 Fasten the left bracket to the vehicle frame with the following

hardware using the two holes as a guide. See Fig. 2.3

Qty Hardware

2 #10 x 3/4” Pan Head Self Drill Screw

2.4 Tighten the lower bolt installed in step 2.2 at this time.

FIGURE 1.2

FIGURE 2.3

(2) Screws

TOOLS REQUIRED:

ANTIFREEZE

TEFLON TAPE

DRAIN PAN

POWER VACUUM BLEEDER (RECOMMENDED)

SNIPS OR KNIFE TO CUT HOSE AND WIRE TIES

REGULAR SCREWDRIVER OR NUT DRIVER FOR HOSE CLAMPS

NUMBER 2 PHILLIPS DRIVER

SCREW GUN

STANDARD & METRIC WRENCHES,

STANDARD & METRIC SOCKETS

RATCHET

DRILL

2-1/16” HOLE SAW OR

2” HOLE SAW & DREMEL TOOL

7/8” HOLE SAW

SAW TO CUT PLASTIC STORAGE

P. 3 of 12

3. Install Defroster Vent

2009-Current with raised center dashboard

(for pre-2009 models see below)

3.1 Position the vent on the driver’s side of the hood and

mark the center of the hole as shown in Figure 3.1.a. The

2” dimensions for the center are measured off the edges of

the flat section of the plastic hood. Note: Be sure to

check under the hood before drilling to make sure there

is no interference. Drill a 2" hole in the hood with a hole

saw. Use a small reamer or Dremel tool to remove more

material in four places for the vent retaining tabs (see

Figure 3.1.b). Test fit the vent frequently so as not to

remove too much material.

3.2 Pull the vent apart and install the listed hardware

through the trim ring to secure the vent to the hood. Do

not over tighten screws or you risk stripping the holes

in the hood or cracking the vent. Re-assemble the vent.

Qty Hardware

4 #8 x 1/2” Flat Head Self Drill Screw

3.3 Open the hood and route the vent hose from the heater

box to the back side of the hood vent. Check the length of

the hose and trim off any excess so that the hood can still

open fully. Leave several inches of slack. Attach the hose

to the hood vent with a heavy duty wire tie. Install a

second wire tie to secure the hose to the vehicle wiring

beneath the dashboard to prevent the hose from dropping

down into the footwell when the hood is closed.

Pre-2009 with Flat Dashboard

3.4 The supplied oval defroster vent can be used on early

model vehicles. It will be centered in the black dash board

as shown in Figure 3.4. Positioning is critical to avoid

interference with components under dash board.

3.5 Connect the 2-1/2” to 2” vent hose adaptor to the

bottom of the oval defroster vent.

3.6 Measure roughly 1” from the back edge of the dash

board to the back edge of the defroster grill. Hold the oval

defroster vent with the adaptor up under the dash to make

sure there is no interference when aligned with the

defroster grill on the top side of the dashboard.

3.6 Once you are sure the location will work, drill through

the dashboard with a 1/8” drill bit through the two outer

holes in the grill.

3.7 Install the grill to the dashboard using the following

hardware.

Qty Hardware

2 #8 x 3/4” Flat Head Sheetmetal Screw

FIGURE 3.1.A

FIGURE 3.4

FIGURE 3.1.B

Approx: 2”

P. 4 of 12

Use These

(2) Plugs

Do Not

Use This

Plug

FIGURE 4.2

3. Install Defroster Vent (continued)

3.8 Make marks in between the grill slats to show the ends

of the openings that the air will pass through. Remove the

defroster grill and use a 7/8” hole saw to drill out the dash

using the marked lines as a guide. Cut between the 2 holes

with a key hole saw or similar cutting tool to make an oval

as seen in Figure 3.8.

3.8 Hold the defroster vent in position under the

dashboard and route the 2” vent hose over to it from the

heater box and trim the hose to length. Be sure to avoid

any moving or sharp parts such as the 4 wheel drive

selector.

3.9 Secure the hose to the vent using one of the supplied

cable ties.

3.10 Position the defroster vent up under the dashboard

and the grill on top of the dashboard and secure them

together with the two flat head sheetmetal screws.

4. Electrical Connections

4.1. Locate an empty switch location in the dash panel and

remove the blank plug. Feed the black switch plug from

the heater wiring through the opening from the back.

Connect the plug to the supplied switch and install the

switch into the dash panel.

4.2 Route the wiring from the switch to the driver’s side

beneath the dashboard. Plug in to the mating connectors

on the vehicle wiring as seen in Figure 4.2. The black and

red heater wire with male terminals should mate up with

the black and red vehicle plug. The black and yellow

heater wire with the male terminals should mate up with

the black and yellow vehicle plug.

4.3 Turn the key on and test heater fan operation. If fan is

not working, check the fuse.

4.4 Install the supplied split loom on the wire harness

making sure to protect wiring from any sharp objects.

FIGURE 3.4

P. 5 of 12

5. Plumbing

5.1 Attach the supplied 10” piece of heater hose to the upper nipple on

the heater box and secure with a small hose clamp. (See Figure 5.1)

5.2 Install the supplied bleeder cap to the end of the hose and secure

with a small hose clamp. Tip the cap forward when installing to

prevent it from hitting the hood. (See Figure 5.1)

5.3 Remove plastic plugs from front right panel under the air intake

and install the supplied plastic snap in hose grommets in their place.

(See Figure 5.3.a) If there are no plugs in the panel, drill (2) 1-1/8”

holes through the cab panel as shown in Figure 5.3.b and install the

supplied plastic snap in hose grommets.

5.4 Route both long sections of heater hose through these holes from

the rear side, along the seat pan, against the center console, up the

firewall, and around the front of the heater box to the nipples. (See

Figure 5.3.a)

5.5 Attach the lower hose coming up from the floorboard to the lower

nipple on the heater box and secure with a small hose clamp. Attach

the upper hose to the nipple on the bleeder cap and secure with small

hose clamp. (See Figure 5.1) Pull any slack back down to the

passenger compartment, leaving enough of a service loop under the

hood to allow the hood to close easily, without kinking the hose.

5.6 Locate the open end of the hose that is connected to the upper

nipple on the heater box and mark it with a marker or cut a notch in it

to show the difference between the two hoses.

FIGURE 5.3.a

FIGURE 5.1

Install

Grommets

Route hoses as

shown by arrows

Upper Heater

Hose

Install Bleeder

Cap Here

Install 10”

Hose on

Upper Nipple

FIGURE 5.3.b

Drill Holes Here

(Soft Side Cab)

P. 6 of 12

5. Plumbing (continued)

5.7 Stack the hoses, one on top of the other, to prevent

kinking in the corner where the center console meets the

seat pan and feed the slack back through the holes under

the air intake. (See Figure 5.6)

5.8 Using the heater hose cover as a guide, drill through

the floorpan with a 5/16” drill bit. Install the heater hose

cover to the floorpan using the hardware listed below.

(See Figure 5.8) (Note: If the cab is Pre 2013, install a

piece of 1” flat rubber to seal the area shown in white.)

Qty Hardware

2 1/4-20 x 3/4” Flange Bolt

2 1/4-20 Flanged Locknut

Caution: While routing the remaining sections of hose,

avoid hot or moving components within the engine

compartment.

5.9 Route the hoses outside the cab under the frame and

over to the drivers side of the engine compartment. (See

Figure 5.9). Utilize existing hose hangers while routing

the new hoses in the engine compartment.

5.10 Use the supplied cable ties to secure the hoses such

that they can not interfere with the rotating rear drive

shaft.

The next steps are broken down by model.

Section A: 825i (2014-Present)

Section B: 825i (Pre-2014)

Section C: 620i and 625i

Section D: HPX Gas Engines

Section E: Diesel Engines

Section A: 825i (2014-Present)

5A.1 Place a drain pan under the vehicle to catch any

spilled coolant.

5A.2 Per Figure 5A.2, cut a 1” section out of the lower

radiator return hose where shown and drain the coolant

from the line.

5A.3 Install the supplied 1” x 1” x 5/8” tee fitting.

Secure with two large hose clamps.

5A.4 Cut the lower heater hose (connected to the lower

nipple on the heater box) to length (save extra) and install

onto the tee using a small hose clamp. Make sure to

rotate the tee to keep the hose from kinking and also to be

sure it avoids the hot exhaust pipe.

FIGURE 5.8

Fasteners

Here

Heater Hose Cover

FIGURE 5.7

Stack Hoses to

Prevent Kinking

FIGURE 5A.1

Cut 1” out of Lower Radiator

Return Hose For Tee Fitting

Lower Heater Hose

P. 7 of 12

FIGURE 5A.6 (2014 engine shown)

2014 Shut-off

Valve Location

Upper Radiator Hose

13” Hose

FIGURE 5A.6

FIGURE 5A.5 (2013 engine shown)

2014 Bypass

Hose Location

5. Plumbing (continued)

5A.5 Remove the short bypass hose that connects the

water pump to the solid radiator return line. See Figure

5A.5 for the approximate bypass hose location.

5A.6 Cut a 7/8” section out of the center of the bypass

hose and install the supplied 5/8” x 5/8” x 5/8” Tee fitting

in the center as shown in Figure 5A.6.

5A.7 Re-install the hose onto the vehicle. Note: it is

easier to temporarily remove the mounting bolts holding

the solid black coolant line in place. Once the bypass

hose with tee fitting is installed, re-install the mounting

bolts.

5A.8 Cut 13” off the leftover lower heater hose. Install

on the tee fitting and secure with a hose clamp. Be sure

to route the hose along the upper radiator hose as shown

in Figure 5A.8.

5A.9 Install the supplied shutoff valve in the end of the

13” hose and secure with a small hose clamp as shown in

Figure 5A.8

5A.10 Check to make sure there are no kinks anywhere

then cut the upper heater hose to length and secure to the

shut-off valve with a small hose clamp.

P. 8 of 12

5. Plumbing (continued)

Section B: 825i (Pre-2014)

5B.1 Disconnect the lower radiator return hose (lower

hose in Figure 5B.1) and drain coolant into a drain pan for

re-use then reconnect hose and clamp.

5B.2 Per Figure 5B.1, cut a 1” section out of the lower

radiator return hose where shown and install the supplied

1” x 1” x 5/8” tee fitting. Secure with two large hose

clamps. Cut the lower heater hose to length (save extra)

and install onto the tee using a small hose clamp. Make

sure to rotate the tee to keep the hose from kinking and

also to be sure it avoids the hot exhaust pipe.

5B.3 Cut 2” and 3” pieces from the leftover lower hose

and attach them to the Y-fitting with hose clamps as

shown in Figure 5B.3.

5B.4 Remove the bleeder fitting from the larger diameter

hose and insert the open end of the y-fitting from step

5B.3 into its place. Rotate the y-fitting to appear as in

Figure 5B.4 and tighten hose clamp.

5B.5 Insert the bleeder fitting into the 3” hose installed in

step 5B.3 and secure with a hose clamp. Cut the small

diameter by-pass hose to length and secure to the open

end of the bleeder fitting.

5B.6 Open the shut off valve completely and install into

the 2” hose installed in step 5B.3 and secure with a small

hose clamp.

5B.7 Cut the upper heater hose to length and attach it to

the shut off valve and secure with a small hose clamp.

3” Hose

2” Hose

FIGURE 5B.3

FIGURE 5B.1

Cut 1” out of Lower Radiator

Return Hose For Tee Fitting

Lower Heater Hose

FIGURE 5B.4 (2013 engine shown)

Install Y-

Fitting Here

Install Shut-

Off Here

Bleeder

Relocated

Upper Heater

Hose

P. 9 of 12

5. Plumbing (continued)

Section C: 620i and 625i

5C.1 Place a drain pan under the vehicle and remove the drain

screw as shown in Figure 5C.1. Once coolant is drained, re-

tighten the drain screw.

5C.2 Per Figure 5C.1, cut a 1” section out of the lower radiator

return hose where shown and install the supplied 1” x 1” x 5/8”

tee fitting. Secure with two large hose clamps. Cut the lower

heater hose to length and install onto the tee using a small hose

clamp. Make sure to rotate the tee to keep the hose from kinking

and also to be sure it avoids the hot exhaust pipe.

5C.3 Cut the upper radiator hose where shown in Figure 5C.3

and install the supplied 1” x 1” x 5/8” tee fitting. Aim the 5/8”

barb downwards and secure with 2 large hose clamps provided.

This will be the supply hose to the heater.

5C.4 Make sure the upper heater hose is not kinked anywhere

and cut it to length. Attach it to the 5/8” barb on the tee fitting

with a small hose clamp.

5C.5 Open the supplied shut off valve completely and install into

the upper hose where it is convenient to use and away from the

exhaust. Secure with small hose clamps.

Section D: HPX Gas Engines

5D.1 Place a drain pan under the vehicle and loosen the engine

block drain screw on the left side of the engine just inside the

radiator return line. Once coolant is drained, re-tighten the drain

screw.

5D.2 Unplug the wire from the sending unit then remove and

save the sending unit and its sealing washer. (See Figure 5D.2)

5D.3 Install the supplied sending unit adaptor with one of the

nylon washers provided. Note: If the port on the side of the

adaptor points toward the engine block, remove the adaptor and

install another nylon washer under it to re-orient it. (See Figure

5D.1)

5D.4 Re-install the sending unit and washer into the top of the

adaptor and reconnect the sending unit wire. (See Figure 5D.1)

5D.5 Install the supplied hose barb into the side of the adaptor,

using thread sealant. (See Figure 5D.1)

5D.6 Route the upper heater hose to this nipple, cut it to length,

and secure with a small hose clamp. (See Figure 5D.1)

5D.7 Open the supplied shut off valve completely and install into

the upper hose where it is convenient to use and away from the

exhaust. Secure with small hose clamps.

5D.7 Cut a 1” section out of the lower radiator return hose

centered on the straight portion of hose just above the oil filter

and install the supplied 1” x 1” x 5/8” tee fitting. Rotate the tee

to aim the 5/8” barb towards the passenger side of the vehicle.

Secure with two large hose clamps.

5D.8 Route the lower heater hose over to the tee fitting, cut it to

length, and install onto the tee using a small hose clamp.

FIGURE 5C.1

Cut 1” out of Lower Radiator

Return Hose For Tee Fitting

Attach Lower

Heater Hose Here

Cut 1” out of Upper Radiator

Hose For Tee Fitting

FIGURE 5C.3

FIGURE 5D.2

Sending Unit

Adaptor

Nylon

Washer(s)

Nipple

Heater

Hose

Wire

Drain

Screw

P. 10 of 12

5. Plumbing (continued)

Section E: Diesel Engines

5E.1 Remove the bolt holding the fuel filter in place and move the

filter out of the way without disconnecting any fuel lines.

5E.2 Place a drain pan under the vehicle and remove the drain

screw as shown in Figure 5E.2.

5E.3 Remove the hex drain fitting and replace with the supplied

nipple. Be sure to use sealant on the threads to prevent leaking.

5E.4 Cut the upper heater supply hose (hose going to the top

nipple on the heater unit) to the correct length and install it on the

hose barb. Secure it with a small hose clamp.

5E.5 Open the supplied shut off valve completely and install into

the upper hose where it is convenient to use and away from the

exhaust. Secure with small hose clamps.

5E.6 Move the drain pan under the vehicle and cut a 1” length of

hose out of the existing vehicle coolant return hose on the

passenger side of the engine just rearward of the drive shaft pillow

block. Install the supplied 1” x 1” x 5/8” tee fitting and secure with

large hose clamps.

5E.7 Route the lower heater hose over to this tee fitting and cut to

length. Secure to the nipple with a hose clamp. Be sure not to kink

the hose when routing.

FIGURE 5E.2

Replace Drain

Screw with Fitting

P. 11 of 12

6. Refilling and Bleeding Air from System

6.1 Make sure heater shut off valve is fully open and the bleeder

cap for the heater (see step 5.2) is open. Loosen the engine bleed

screw/bolt. (see Figure 6.1.A,B,C,D) Do not remove the screw.

Just back it out 3-4 turns.

825i: Located on top of the engine in the T-fitting

620i + 625i: located on the intake manifold

HPX Gasoline: Located on the engine intake manifold

Diesel: Located on the engine thermostat housing

6.2 Remove the radiator cap and add coolant to the radiator until

it runs out of the bleed screw.

6.3 Tighten the bleed screw and continue to fill the radiator and

replace the cap.

6.4 Add coolant to the bleeder cap for the heater (see step 5.2) to

fill the upper heater hose, heater core, and lower heater hose until

no more air comes out and replace the cap.

6.5 Add coolant to the recovery tank until it is filled to the top

line.

Warning: If overheat light on the dashboard does come on in

the next steps, shut the engine off immediately and monitor

the level of coolant in the recovery tank to make sure it stays

full. Allow engine to cool completely.

6.6 Start engine and run the vehicle at medium throttle. (Diesel

should run at full throttle). Run engine until the radiator fan turns

on. Check the temperature of the lower radiator hose and heater

hoses.

If cold shut off the engine and allow it to cool. Monitor the level

of coolant in the recovery tank to keep it filled to the upper line

during cool down. Then repeat steps 6.1 – 6.6.

If the lines are warm, allow engine to run at idle until the fan

shuts off then turns on again. If the warning light has not come

on, shut the engine off. Add coolant to the recovery tank until it

reaches the upper line and monitor until the engine is cooled

down.

Fig. 6.1.A (825i Shown)

Bleed Here

Fig. 6.1.B (HPX Gasoline)

Bleed Here

Fig. 6.1.C (620i + 625i)

Fig. 6.1.D (Diesel Shown)

Bleed Here

P. 12 of 12

6. Refilling and Bleeding Air from System (cont.)

The cooling systems on these vehicles can sometimes be very

difficult to bleed. If the bleeding procedure was unsuccessful

or was successful but you are not getting much heat out of the

heater, try the following:

A. Temporarily clamp the upper radiator hose shut. Start

and rev the engine until the heater blows hot air or the

temp light comes on. If the temp light comes on, shut off

the engine immediately and make sure the overflow bottle

is full. Allow the engine to cool and repeat procedure.

Once successful, remove the clamp.

If that does not work, try the following:

B. Start engine and run heater until both lines feel warm.

Continue to run engine until radiator fan cycles. If the

overheat warning light does not come on, then the system

is properly bled. If overheat light does come on, shut the

engine off. Make sure overflow bottle is full. Using cau-

tion to avoid burns and wearing a face shield and

gloves, use pliers to crack open the heater bleeder valve

and allow air to vent until hot coolant flows and quickly

close valve.

7. Re-Install Underhood Storage (pre-2009)

If you installed the oval vent grill in the dashboard, the under-

hood storage compartment can be partially salvaged. If you

have the round vent through the hood the compartment will no

longer fit.

7.1 Cut the passenger side of the storage compartment off

using a saw as shown in Figure 7.1.

8. Install Underhood Vinyl Sealing Panel

8.1 Orient the supplied vinyl panel under the hood as shown

in Figure 8.1.

8.2 Install the supplied Velcro to the steel frame components

around the perimeter of the vinyl. Use the vinyl panel as a

guide for Velcro location. The frame components must be

cleaned and should be at room temperature for best adhesion.

8.3 Depending on vehicle wiring or any other accessory rout-

ing, you may need to cut the vinyl to best fit with any obsta-

cle. If you installed the underhood storage compartment in

section 7 the vinyl will need to be cut to fit underneath it.

9. Proper Operation

In warm weather, shut off the valve to stop coolant flow to the

heater. The fan will still be operable for defogging or air cir-

culation. Note: Be sure to wear a glove when handling the

shut-off valve because the valve will be hot.

When cold weather returns, simply open the valve and heat

will be restored.

Figure 7.1

Figure 8.1