Whelen MBPI06AA - Manual (Page 2)

Page 2
Remove reflector.
and remove 7MM
bolt underneath.
Pull off inner plate
and remove three
10mm bolts.
Follow factory
harness when
routing cable.
Unhook the
door handle
cable.
Fig. 1
Remove cover from
door pull and remove
torx bolt underneath.
Remove cover from
door handle and remove
torx bolt underneath.
Arrows indicate location
of 7 christmas tree fasteners
holding on door panel.
Do not allow the
leading edge of
the tape to extend
beyond the leading
edge of the housing
Removing and Preparing the Mirror Assembly:
1. Pull off the inner plate covering the inside of the mirror which is held on with 2 clips (Fig. 1).
2. Remove the covers from behind the door pull and door handle then remove the Torx head bolts underneath.
3. Remove the door reflector and remove the 7mm bolt underneath.
4. Loosen the door panel using an upholsterers tool to disengage the 7 fasteners located around the outside (Fig. 1). Unhook the door handle
cable and remove the door panel.
5. Remove the mirror assembly by removing the three, 10mm bolts that hold it on. Measure 1-1/4” from the inside of the top edge of the mirror
assembly body and 3-1/2” from the upper seam that runs around the front of the mirror assembly and drill a 3/8” hole into the the mirror
assembly at this location (Fig. 2).
WARNING! The location of this hole is critical! Be sure that all of the distances are measured accurately. Failure to do so could result in
damage to the mirror’s motor and/or wiring components! Use a drill stop to prevent the bit from penetrating too deeply.
Preparing the Wire Harness:
NOTE: Because the harness must be routed through a specific, narrow and twisting path within the
mirror assembly, it is necessary to temporarily extend the length of the harness.
1. Locate the ty-wrap included with your mirror beam and cut the fastener-end off.
2. Locate the end of the Mirror-Beam™ harness that has SOCKET-type terminals installed on the free
wires. On strobe models, cut off the non-insulated wire.
3. Strongly secure the ty-wrap to the harness with electrical or similar tape (Fig. 4). Although the purpose of
this procedure is to extend the harness length as much as possible, it is important to have a sufficient
length of the tie-wrap secured to the harness (2” minimum).
Routing the Wire Harness:
1. Insert the ty-wrap into the opening drilled previously. Feed the tie-wrap into the mirror cavity and out of the mirrors wire hole. There should
not be more than 4 - 5” of harness sticking out of the hole. If the length is different from this, adjust harness length accordingly.
2. The ty-wrap is now removed from the harness and the wire terminals inserted into their supplied connectors (see wiring last page).
WARNING! All customer supplied wires that connect to the positive terminal of the battery must be sized to supply at least 125% of the
maximum operating current and FUSED at the battery to carry the load. DO NOT USE CIRCUIT BREAKERS WITH THIS PRODUCT!
Affixing Mirror-Beam Housing to Mirror Assembly:
Note: The following procedure requires that the mirror assembly be no colder than 60°F (18°C).
1. Thoroughly clean the plastic mirror assembly and the inside surface of the Mirror-Beam housing using a 50/50 mixture of isopropyl (not
rubbing) alcohol and water. Allow to dry completely.
2. Position the Mirror-Beam housing onto the mirror assembly. Apply sufficient pressure to simulate its permanently mounted position.
3. Note the edge of the Mirror-Beam™ housing in relation to the mirror assembly. Later, when applying the tape to the mirror assembly, do not
allow any of the tape surface to extend beyond the leading edge off the Mirror-Beam housing (Fig. 3).
Fig. 3
Fig. 4
3-1/2"
1-1/4"
SEAM
Fig. 2