16
VW BUS T4 Installation instructions instal.instr.no. 75110FH05/04 part-no. 75110 Production of Car-Audio-Systems Porsche Str. 15 70794 Filderstadt Tel. 00 49 71 58 / 9 56 99-0 Fax 00 49 71 58 / 9 56 99-10 e-mail: [email protected] www.jehnert.com

VW BUS T4 - jehnert.de

  • Upload
    others

  • View
    34

  • Download
    2

Embed Size (px)

Citation preview

Page 1: VW BUS T4 - jehnert.de

SoundSoundD E S I G N

JEHNERT

VW

BU

S T

4

G u a r a n t e e

2004/by.aj/FH - 15 -

Installation instructions

inst

al.i

nst

r.n

o.

75

11

0FH

05

/04 part-no. 75110

Jehnert Sound Designdevelopment and

production ofCar-Audio-Systems

Heinrich-Hertz-Str. 1170794 Filderstadt

Tel.: 0049-711-77 97 87- 87Fax: 0049-711-77 78 921

e-mail: [email protected]

We grant a manufacturers guarantee of 2 years starting from the date of purchaseof the door panels or sound system from the dealer.

Within this guarantee period to our choice we either repair or replace free ofcharge all defects due to material or workmanship.

Exempt from this guarantee are damages due to improper use, wear and tear ordamages which have to be led back on wear or interventions by third parties.The guarantee does not cover subsequent damages or such defects that onlyinsignificantly impair the value or the usability of the panels/sound system.The guarantee does not cover damages due to external influences.

Panels with additional or wrong assembly drill holes cannot be returned. These are damages to the panel which cannot be repaired again.

Production ofCar-Audio-Systems

Porsche Str. 1570794 Filderstadt

Tel. 00 49 71 58 / 9 56 99-0Fax 00 49 71 58 / 9 56 99-10

e-mail: [email protected]

Production ofCar-Audio-Systems

Porsche Str. 1570794 Filderstadt

Tel. 00 49 71 58 / 9 56 99-0Fax 00 49 71 58 / 9 56 99-10

e-mail: [email protected]

Page 2: VW BUS T4 - jehnert.de

Packing list .......................................................................... 2

1. Disassembly of the door lining .............................................. 3

2. Installation midrange and tweeter in the dashboard ................ 4

3. Panel alignment ................................................................... 5

4. Handling of doorlining / Installation door panel ..................... 6

5. speaker cables / Handling of car doors .................................. 7

6. Insulation of the door lining / car doors ................................. 8

7. Installation of the door lining onto the car doors .................... 9

8. Crossover circuit - Speaker connection .................................. 10

Lodspeaker wiring diagram .................................................. 11

9. Installation of the speaker-grills ............................................ 12

Technical Information .......................................................... 13

Service / fault diagnoses ....................................................... 14

Guarantee .......................................................................... 15

page

75110 VW Bus T 4 - 1 - © JEHNERT SOUND DESIGN

C o n t e n t s

Particularly important notes contain the following remarks:

Please follow the installation instructions“step by step”

and check the package contents

Steffen KretzschmarSaddlery / Completion

75110 VW Bus T 4 - 14 - © JEHNERT SOUND DESIGN

Technical questions Hotline: 0049-711-77 97 87-87

We thank you for your support!

Mirko SchwarzDevelopment

It is our pleasure to help you!

Dear customer,

We have taken great care to explain the procedures in our installation instructionsmore detailed and “step by step”.

Your tips and suggestions help us for the future to eliminate uncertainties andmisinterpretation. Therefore, please inform us. what you would like to be improvedor what we should still change.

Marc SitterExport / ServiceMarc Sitter

Export / Service

The following notes serve to help troubleshoot and eliminate faults or malfunctionson your own. If the following measures are not effective, please call us.

What can it be if ... possible cause/ solution

..it doesn’t sound right. wrong polarity on the subwoofers ( page 10) crosover circuit attached wrong ( page 11)

Doorlining and moisture protection foil not cut out ( page 6+9)

amplifier doesn’t have enough power ( page 13)

amplifier connection

...it doesn’t fit correctly. door panel customization ( page 5)

installation of the panels on the door lining (page 6)

.....grills do not hold. observe notes on page 12!

vibrations insulation, see notes on page 8

Self-help and fault diagnosis

The following notes serve to help troubleshoot and eliminate faults or malfunctionson your own. If the following measures are not effective, please call us.

What can it be if ... possible cause/ solution

..it doesn’t sound right. wrong polarity on the subwoofers ( page 10) crosover circuit attached wrong ( page 11)

Doorlining and moisture protection foil not cut out ( page 6+9)

amplifier doesn’t have enough power ( page 13)

amplifier connection

...it doesn’t fit correctly. door panel customization ( page 5)

installation of the panels on the door lining (page 6)

.....grills do not hold. observe notes on page 12!

vibrations insulation, see notes on page 8

Self-help and fault diagnosis

Technical questions: Hotline 00 49 71 58 / 9 56 99-0

Page 3: VW BUS T4 - jehnert.de

Packing unit Check list

door panel, covered (right / left)

Speaker grill, covered (right / left)

tweeter 26 mm

midrange 100 mm Q

Adapter for midrange and tweeter

woofer 160 mm (each mounted on the paneel with 4 sheet metal-screws)

crossover (right / left)

standard cables for subwoofer (right / left)

Hardware bag: flat head screws M 4 x 60

metal screws, 3,9 x 25(for angle fastening)

metal screws, 5,0 x 80

metal screws, 5,0 x 90

sheet metal screws, black 3,9 x 13 (for tweeter mounting)

sheet metal nuts ø 3,9 mm

Hex nut M4

Washer Ø 20mm for metric screws 10x + 4x as spacer for Velcro fastener

Velcro strip à 2,5 cm (reserve)

Preassembled hardware: Velcro fastener plus strips

flat head screws M 4 x 16

flat head screws M 4 x 50

flat head screws M 4 x 30 (right side)

flat head screws M 4 x 40 (left side)

sheet metal screw, black 3,9 x 13 (for woofer)

sheet metal screw, black 3,5 x 13 (for velcro fastener)The product was carefully packed and checked for its completeness. If you find anything missing, damaged ordefective, please notice our guarantee services on the back of these assembly instructions.

Packing list 75110

75110 VW Bus T 4 - 13 - © JEHNERT SOUND DESIGN 75110 VW Bus T 4 - 2 - © JEHNERT SOUND DESIGN

2

2

2

2

2

32

2

2

4

4

8

2

2

4

10

14

4

16

2

2

1

1

32

16

T e c h n i c a l i n f o r m a t i o nEquipment: electric window control

Model/ year: T 4

Insulation: is absolutely necessary ! - see page 8

Note about setting: To obtain optimal stereoscopic sound, all settings on the radio (bass, treble, loudness etc) should be set to zero or neutral.

Recommendedamplifier power : from 2x 200 - 360 Watt RMS / 4 Ohm

Metal cutwork : not necessary

Cut-outs for loudspeaker/ 4 x 144mm (max.outer dimensions subwoofer 165 mm)each side (max.installation depth subwoofer 65 mm)

DIN-Euro-Norm-standard basket ø 6“ made it fit

Sound-System: 3-ways 4 x 160 mm subwoofer/ side

1 x 100 mm midrange / side 1 x 26 mm tweeter / side car-customized crossover network

max.continuous Watt/RMS: 2 x 300/500Watt car specific frequency range: 39-22.000 Hz Total impedance: 4 Ohm

We reserve the right to make technical changes, as well as development.

4

4

6

2

2

3

2

4

10

14

4

flat head screws M4 x 60

Spax screws 3,9 x 25 (for angle fastening)

Spax screws 5,0 x 80

Spax screws 5,0 x 90

Spax screws 5,0 x 100

flat round head screw 3,9 x13

sheet metal screws black 3,9 x 10 (for tweeter mounting)

sheet metal nut Ø 3,9

hex nut M4

washers Ø 20mm

velcro strip 2,5 cm (Reserve)

165

Page 4: VW BUS T4 - jehnert.de

Removing the grills:The Velcro fasteners stick together very strongly!The grills can be removed anytime by carefully lifting them off.Please, avoid any way of forceful yanking at the grills.It could break!

9.3.

9.2. Our Tip: If the panel cannot be pressed on completely at some points. . .

Cause: the special form at these points and the resulting differences inmaterial cross section of the grill.

Solution: the distance can be levelled out with spacers 3 under theVelcro disc.(Spacers included with the screw kit)

9.1. Precisely align and carefully press grill into the Velcro fasteners.

The Velcro fastener makes a crackling sound when it is closed correctly.

1.1. roll down window completely

1.2. pry out the plastic bolt (A) at the door-innerside and pry out the plastic cap at the door lock (B).

A

B

C

1.3. pry out the plastic cap at the door handle (C) abhebeln and unscrew the 3 cross head screws underneath.

BA

1.4. carefully remove the plastic clips on the door-lining edges and move the door-lining forward away from the inner door metal

1.5. disconnect the original loudspeaker and remove the Bowden pull wire.

1.6. Loosen the screws of the original tray fastening and remove the tray.

C1C2

C3

1 . Disassembly of the door lining

75110 VW Bus T 4 - 3 - © JEHNERT SOUND DESIGN 75110 VW Bus T 4 - 12 - © JEHNERT SOUND DESIGN

9. Installation of the speaker’s grill:

grill

2 self-adhesive Velcro-strip

1 Velcro fastener

3 Washer M4 ø 20 as spacer

doorpanel

1.4. Unclip speaker grill. Dismount speakers and unsrew the 3 cross head screws underneath..

1.5. Carefully remove the plastic clips on the doorlining edges and move the doorlining forward away from the inner door metal.

1.6. Remove the Bowden pull wire..

1.7. Loosen the screws of the original tray fastening and remove the tray.

Page 5: VW BUS T4 - jehnert.de

Loudspeaker wiring diagram

Connect all loudspeakers and crossover circuits:

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

Mi

dr

an

ge

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

Loudspeaker wiring diagram

Connect all loudspeakers and crossover circuits:

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

Mi

dr

an

ge

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

Tw

ee

te

r

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

2.1. tweeter installation on the A-pillar:2.1.1. Lead the tweeter cable throgh the opening in the mounting bowl and lengthen it with the speaker cable (1,5 - 4 mm2). Measure the cable length up to the mount of the crossover under the dashboard (see page 9)

2.1.2. place the tweeter bowl directly above the original speaker grill - parallel to the front glas:

for acoustical reasons the tweeter must radiate parallel to the front glass and has not to be directed to the hearer!

Affix the mounting bowl with a sheet metal screw 3,9x13 to the A-pillar. Insert tweeter and fasten it with a bajonet socket.

2.2. midrange installation in the dashboard:2.2.1. pry out the speaker grill and remove the original speaker.

2.2.2. connect the JEHNERT-midrange with a speaker cable (1,5 - 4 mm2) Lead the cable to the mount of the crossover in the dashboard (page 9)

2.2.3. insert the midrange with installation installation ring into the original mount so thhat the fastening cover plates on the midrange match the original fastening points. Fasten with original screws.

IMPORTANT:Tweeter-position radiateparallel to the front glas !

75110 VW Bus T 4 - 11 - © JEHNERT SOUND DESIGN

2. midrange and tweeter installation in the dashboard

75110 VW Bus T 4 - 4 - © JEHNERT SOUND DESIGN

Circuit diagram of 2-way crossover / 4x subwoofer

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

WO

OF

ER

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

WO

OF

ER

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

WO

OF

ER

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

WO

OF

ER

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

tweeterwoofer

SoundSoundD E S I G N

JEHNERT

midrangeINPUT

3-way crossover circuit

VW BUS T 4

= set of cables supplied w

ith

amplifier

from 200 W

att RM

S / 4 Ohm

recomm

ended power 10

Insert midrange with installation ring.

Fastening left 1x with the screw 3,9 x 13

Fastening right 2xwith the screws 3,9 x 13

Page 6: VW BUS T4 - jehnert.de

3. Panel alignment

For doorlinings with ventilation flap:

Some models are equipped with a ventilation flap on the below part of the door lining.It must absolutely be sealed or closed!

3.1. Place the door lining on a plane surface.

3.2. Dismount the loudspeakers attached to the panel for transport protection. Retain the screws for later assembly.

3.3. Place the panel without loudspeakers on the door lining and align it:Align the upper edge of the panel directly on the dept under the

door handle.

Only precise alignment of the panel with the door liningwarrants optimal fit.

fig.: backside of the panel

picture to page 6 - No.5: fastening points - Panel backside

75110 VW Bus T 4 - 5- © JEHNERT SOUND DESIGN

8. Crossover circuit - Speaker connection

8.1. precable crossovers - see fig. page 11.

8.2. Recommendation crossover installation: on option under the dashboard

IMPORTANT: Do not install the crossover immediately next to electrical equimpent

8.3. Insert subwoofer and connect all loudspeakers to the crossover circuit with the included standard cables for subwoofer to the crossover circuit: parallel wiring see diagram on page 11.

Notice: You should check the polarity of all subwoofers before connecting them to the crossover circuit with a 9 volt battery:

pole of the crossover circuit input to of a 9 Volt battery

pole of the crossover circuit input to of a 9 Volt battery

All subwoofers must move uniformly!

Wrong polarity of a subwoofer can totally equalize the bass sound!

75110 VW Bus T 4 - 10 - © JEHNERT SOUND DESIGN

fastening angular for metal screws 5,0 x 30

Reference l ine

1M 4 x 16alreadymounted

2 3M 4 x 50alreadymounted

M 4 x 30alreadymounted

You should check the polarity of all woofers after having connected them to the crossover circuit with a 9 volt battery (input cable on the side of the amplifier

3,9 x 25

Page 7: VW BUS T4 - jehnert.de

1. use the precisely aligned panel as template in order to mark fastening points 1- 7:• mark the fastening points 1-3_ premounted in the panel: pressing the panel to the door lining leaves visible impressions of the screws

• marking of fixing points 4-7: use a thin awl to set the marks on the door-lining

TIP to mark angular fastening points 6+7:put in a little bit of packing tape to this position. Measure up the angular position.

Mark panel edge and angular position on the tape.

2. draw the speakers’ cut-outs onto the door-lining.

3. take away the door build. cut out the speakers’ outlines marked by means of a compass saw

4. Drill the holes for the screws according to the marks set before. Use a 6mm drill. (fastening point 1 = 10mm)

5. place the door panel precise again and do the panel fastening in in exactly follow succession:

fastening from the doorlining - backside

1. fastening points 1-3 secure with washers and nuts

(fig. see page 5)

2. fastening points 6+7 screw in the metal-screws 3,9 x 25 into the angular fastening and secure with sheet metal nuts ø 3,9 mm.

fastening points 4+5 fromdoorlining - frontside:screw in both M4x 60 Screws

and secure with washers and nuts

All cutting edges of the panel must fit to the door lining snuglyall around without gap

7. installation of the door-lining onto the the car doors

7.1. Check up length of the screws and bolts:

in order to prevent damages of mechanic parts of the car doors, please check once again the length of all bolts and screws on the back side of the door lining! No touch with any mechanic parts of the car doors ! (please shorten if necessary).

7.2. put the door-lining into the upper sealing of the car door tip: grease the upper door sealing with a residue-free lubricant before

7.3. fit it in contrary order of succession as described on page no. 3

7.4. carefully screw in the metal screws 8-12 through the door panel and the door lining to the door metal.

IMPORTANT: Do not screw in the self cutting metal screws too tight - it deforms the doormetal and affects the normal function of the door mechanic!

fastening point 8-11: metal screw 5,0 x 80 12: metal screw 5,0 x 90

4. Handling of door lining / Panel installation - Fastening

fastening points 8 - 12 : no pre-drilling fastening with metal screws has to be done directly if installing the the complete doorling onto the car door (see page 9)

6+7= fastening angular - panel backside - fig see page 5, too

Spax 3,9 x 25 Spax 3,9 x 25

75110 VW Bus T 4 - 9 - © JEHNERT SOUND DESIGN 75110 VW Bus T 4 - 6 - © JEHNERT SOUND DESIGN

8

9 1011

4 512

6= 7=

1 2 3

891011

12

IMPORTANT: Strong tightening of the screwsaffects the function of the door mechanic!

Final inspection after panel installation:

• please check all functions of the operating elements such as seat adjustment, opening of the glove box, window winder etc.• no insulation directly behind the speaker !

M 4 x 60 M 4 x 60

1. use the precisely aligned panel as template in order to mark fastening points 1- 7:• mark the fastening points 1-3_ premounted in the panel: pressing the panel to the door lining leaves visible impressions of the screws

• marking of fixing points 4-7: use a thin awl to set the marks on the door-lining

TIP to mark angular fastening points 6+7:put in a little bit of packing tape to this position. Measure up the angular position.

Mark panel edge and angular position on the tape.

2. draw the speakers’ cut-outs onto the door-lining.

3. take away the door build. cut out the speakers’ outlines marked by means of a compass saw

4. Drill the holes for the screws according to the marks set before. Use a 6mm drill. (fastening point 1 = 10mm)

5. place the door panel precise again and do the panel fastening in in exactly follow succession:

fastening from the doorlining - backside

1. fastening points 1-3 secure with washers and nuts

(fig. see page 5)

2. fastening points 6+7 screw in the metal-screws 3,9 x 25 into the angular fastening and secure with sheet metal nuts ø 3,9 mm.

fastening points 4+5 fromdoorlining - frontside:screw in both M4x 60 Screws

and secure with washers and nuts

All cutting edges of the panel must fit to the door lining snuglyall around without gap

7. installation of the door-lining onto the the car doors

7.1. Check up length of the screws and bolts:

in order to prevent damages of mechanic parts of the car doors, please check once again the length of all bolts and screws on the back side of the door lining! No touch with any mechanic parts of the car doors ! (please shorten if necessary).

7.2. put the door-lining into the upper sealing of the car door tip: grease the upper door sealing with a residue-free lubricant before

7.3. fit it in contrary order of succession as described on page no. 3

7.4. carefully screw in the metal screws 8-12 through the door panel and the door lining to the door metal.

IMPORTANT: Do not screw in the self cutting metal screws too tight - it deforms the doormetal and affects the normal function of the door mechanic!

fastening point 8-11: metal screw 5,0 x 80 12: metal screw 5,0 x 90

4. Handling of door lining / Panel installation - Fastening

fastening points 8 - 12 : no pre-drilling fastening with metal screws has to be done directly if installing the the complete doorling onto the car door (see page 9)

6+7= fastening angular - panel backside - fig see page 5, too

Spax 3,9 x 25 Spax 3,9 x 25

75110 VW Bus T 4 - 9 - © JEHNERT SOUND DESIGN 75110 VW Bus T 4 - 6 - © JEHNERT SOUND DESIGN

8

9 1011

4 512

6= 7=

1 2 3

891011

12

IMPORTANT: Strong tightening of the screwsaffects the function of the door mechanic!

Final inspection after panel installation:

• please check all functions of the operating elements such as seat adjustment, opening of the glove box, window winder etc.• no insulation directly behind the speaker !

M 4 x 60 M 4 x 60

Beginning with fastening point 1.

Page 8: VW BUS T4 - jehnert.de

5. Speaker cables / Preparation of the car doors

5.1. Installation speaker cables 5.1.1. Lead 1 speaker cable (1,5 - 4 mm2) from the amplifier to the cross- over under the dashboord.

5.1.2. Lead 1 speaker cable (1,5 - 4 mm2) from the crossover into the car door (see wiring diagram page 11)

5.2. IMPORTANT! Preparation of the car doors:

5.2.1. remove the original insulation material (foil) completely!

5.2.2. in order to protect the speakers against humidity close all cut-outs / depts on the inner door metal with tar mats or similar insulation material.

5.2.3. to avoic vibration noise tighten all original fastening screws on the inner door metal.

5.2.4. please observe that the speaker cables are not squeezed by any mechanic parts (window contrrol etc.)

5.2.5. IMPORTANT CONTROL: hold the door lining with the panel to the car door and check the following at the 1. speaker cut-out (see fig.):

• the factory installed clipped cable has to be displaced downward instead of the 1 st woofer in the panel.

• if need be, knock the door metal internally on this part - the woofer in the panel must not be in contact with the door metal.

IMPORTANT: insulate the car door - see description on page 8

IMPORTANT CHECK(only for the 1st woofer installation)

displace the originalclipped cable downwardand slightly knock thedoor metal internally

75110 VW Bus T 4 - 7 - © JEHNERT SOUND DESIGN 75110 VW Bus T 4 - 8 - © JEHNERT SOUND DESIGN

6. insulation of the door lining

Important tip: the use of 4x160mm mid-woofer /side may cause vibrations which lead to annoying rattle noises in the car door

some helpful tips:• use our self-adhesive insulation fleece (art.no.: 27000) or a foam material for the backside of the door lining (see fig. above) or

• stabilize the backside of the door lining by means of a special material(Glass Fibre Filler or stiffening material)

Important: keep the cut-outs for the door-airbags and speakers open• affix the *backside of the inner door metal with self-adhesive asphalt mats (see fig. * )

• by knocking on the car door, vibrations caused by mechanic parts (e.g. Bowden pull wire etc. ) and wiring harness may be found out. Cover these parts with foamed material, felt or something like that

• cut off overlapping cable tie (rattle noise)

• adhere felt or foamed material under the original wiring harness

!

Important:No insulation material behind- loudspeaker- door latch lever- (fig. A): drill a hole for the installation clip

fig.: example backside of the door lining – insulation with our article no.: 27000

moisture protection foil

front side ofinner door metal

* door metal outside = back side of the inner door metal

attention – danger !!No insulation behind theside-airbags (fig. B)

Page 9: VW BUS T4 - jehnert.de

5. Speaker cables / Preparation of the car doors

5.1. Installation speaker cables 5.1.1. Lead 1 speaker cable (1,5 - 4 mm2) from the amplifier to the cross- over under the dashboord.

5.1.2. Lead 1 speaker cable (1,5 - 4 mm2) from the crossover into the car door (see wiring diagram page 11)

5.2. IMPORTANT! Preparation of the car doors:

5.2.1. remove the original insulation material (foil) completely!

5.2.2. in order to protect the speakers against humidity close all cut-outs / depts on the inner door metal with tar mats or similar insulation material.

5.2.3. to avoic vibration noise tighten all original fastening screws on the inner door metal.

5.2.4. please observe that the speaker cables are not squeezed by any mechanic parts (window contrrol etc.)

5.2.5. IMPORTANT CONTROL: hold the door lining with the panel to the car door and check the following at the 1. speaker cut-out (see fig.):

• the factory installed clipped cable has to be displaced downward instead of the 1 st woofer in the panel.

• if need be, knock the door metal internally on this part - the woofer in the panel must not be in contact with the door metal.

IMPORTANT: insulate the car door - see description on page 8

IMPORTANT CHECK(only for the 1st woofer installation)

displace the originalclipped cable downwardand slightly knock thedoor metal internally

75110 VW Bus T 4 - 7 - © JEHNERT SOUND DESIGN 75110 VW Bus T 4 - 8 - © JEHNERT SOUND DESIGN

6. insulation of the door lining

Important tip: the use of 4x160mm mid-woofer /side may cause vibrations which lead to annoying rattle noises in the car door

some helpful tips:• use our self-adhesive insulation fleece (art.no.: 27000) or a foam material for the backside of the door lining (see fig. above) or

• stabilize the backside of the door lining by means of a special material(Glass Fibre Filler or stiffening material)

Important: keep the cut-outs for the door-airbags and speakers open• affix the *backside of the inner door metal with self-adhesive asphalt mats (see fig. * )

• by knocking on the car door, vibrations caused by mechanic parts (e.g. Bowden pull wire etc. ) and wiring harness may be found out. Cover these parts with foamed material, felt or something like that

• cut off overlapping cable tie (rattle noise)

• adhere felt or foamed material under the original wiring harness

!

Important:No insulation material behind- loudspeaker- door latch lever- (fig. A): drill a hole for the installation clip

fig.: example backside of the door lining – insulation with our article no.: 27000

moisture protection foil

front side ofinner door metal

* door metal outside = back side of the inner door metal

attention – danger !!No insulation behind theside-airbags (fig. B)

165mm

for

Page 10: VW BUS T4 - jehnert.de

1. use the precisely aligned panel as template in order to mark fastening points 1- 7:• mark the fastening points 1-3_ premounted in the panel: pressing the panel to the door lining leaves visible impressions of the screws

• marking of fixing points 4-7: use a thin awl to set the marks on the door-lining

TIP to mark angular fastening points 6+7:put in a little bit of packing tape to this position. Measure up the angular position.

Mark panel edge and angular position on the tape.

2. draw the speakers’ cut-outs onto the door-lining.

3. take away the door build. cut out the speakers’ outlines marked by means of a compass saw

4. Drill the holes for the screws according to the marks set before. Use a 6mm drill. (fastening point 1 = 10mm)

5. place the door panel precise again and do the panel fastening in in exactly follow succession:

fastening from the doorlining - backside

1. fastening points 1-3 secure with washers and nuts

(fig. see page 5)

2. fastening points 6+7 screw in the metal-screws 3,9 x 25 into the angular fastening and secure with sheet metal nuts ø 3,9 mm.

fastening points 4+5 fromdoorlining - frontside:screw in both M4x 60 Screws

and secure with washers and nuts

All cutting edges of the panel must fit to the door lining snuglyall around without gap

7. installation of the door-lining onto the the car doors

7.1. Check up length of the screws and bolts:

in order to prevent damages of mechanic parts of the car doors, please check once again the length of all bolts and screws on the back side of the door lining! No touch with any mechanic parts of the car doors ! (please shorten if necessary).

7.2. put the door-lining into the upper sealing of the car door tip: grease the upper door sealing with a residue-free lubricant before

7.3. fit it in contrary order of succession as described on page no. 3

7.4. carefully screw in the metal screws 8-12 through the door panel and the door lining to the door metal.

IMPORTANT: Do not screw in the self cutting metal screws too tight - it deforms the doormetal and affects the normal function of the door mechanic!

fastening point 8-11: metal screw 5,0 x 80 12: metal screw 5,0 x 90

4. Handling of door lining / Panel installation - Fastening

fastening points 8 - 12 : no pre-drilling fastening with metal screws has to be done directly if installing the the complete doorling onto the car door (see page 9)

6+7= fastening angular - panel backside - fig see page 5, too

Spax 3,9 x 25 Spax 3,9 x 25

75110 VW Bus T 4 - 9 - © JEHNERT SOUND DESIGN 75110 VW Bus T 4 - 6 - © JEHNERT SOUND DESIGN

8

9 1011

4 512

6= 7=

1 2 3

891011

12

IMPORTANT: Strong tightening of the screwsaffects the function of the door mechanic!

Final inspection after panel installation:

• please check all functions of the operating elements such as seat adjustment, opening of the glove box, window winder etc.• no insulation directly behind the speaker !

M 4 x 60 M 4 x 60

fastening point 8: Spax 5 x 90 9-11: Spax 5 x 80 12: Spax 5 x 100

Page 11: VW BUS T4 - jehnert.de

3. Panel alignment

For doorlinings with ventilation flap:

Some models are equipped with a ventilation flap on the below part of the door lining.It must absolutely be sealed or closed!

3.1. Place the door lining on a plane surface.

3.2. Dismount the loudspeakers attached to the panel for transport protection. Retain the screws for later assembly.

3.3. Place the panel without loudspeakers on the door lining and align it:Align the upper edge of the panel directly on the dept under the

door handle.

Only precise alignment of the panel with the door liningwarrants optimal fit.

fig.: backside of the panel

picture to page 6 - No.5: fastening points - Panel backside

75110 VW Bus T 4 - 5- © JEHNERT SOUND DESIGN

8. Crossover circuit - Speaker connection

8.1. precable crossovers - see fig. page 11.

8.2. Recommendation crossover installation: on option under the dashboard

IMPORTANT: Do not install the crossover immediately next to electrical equimpent

8.3. Insert subwoofer and connect all loudspeakers to the crossover circuit with the included standard cables for subwoofer to the crossover circuit: parallel wiring see diagram on page 11.

Notice: You should check the polarity of all subwoofers before connecting them to the crossover circuit with a 9 volt battery:

pole of the crossover circuit input to of a 9 Volt battery

pole of the crossover circuit input to of a 9 Volt battery

All subwoofers must move uniformly!

Wrong polarity of a subwoofer can totally equalize the bass sound!

75110 VW Bus T 4 - 10 - © JEHNERT SOUND DESIGN

fastening angular for metal screws 5,0 x 30

Reference l ine

1M 4 x 16alreadymounted

2 3M 4 x 50alreadymounted

M 4 x 30alreadymounted

You should check the polarity of all woofers after having connected them to the crossover circuit with a 9 volt battery (input cable on the side of the amplifier

You should check the polarity of all woofers after having connected them to the crossover circuit wit a 9 volt battery(input cable on the side of the amplifier).

Page 12: VW BUS T4 - jehnert.de

Loudspeaker wiring diagram

Connect all loudspeakers and crossover circuits:

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

Mi

dr

an

ge

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

Loudspeaker wiring diagram

Connect all loudspeakers and crossover circuits:

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

Mi

dr

an

ge

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

Tw

ee

te

r

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

2.1. tweeter installation on the A-pillar:2.1.1. Lead the tweeter cable throgh the opening in the mounting bowl and lengthen it with the speaker cable (1,5 - 4 mm2). Measure the cable length up to the mount of the crossover under the dashboard (see page 9)

2.1.2. place the tweeter bowl directly above the original speaker grill - parallel to the front glas:

for acoustical reasons the tweeter must radiate parallel to the front glass and has not to be directed to the hearer!

Affix the mounting bowl with a sheet metal screw 3,9x13 to the A-pillar. Insert tweeter and fasten it with a bajonet socket.

2.2. midrange installation in the dashboard:2.2.1. pry out the speaker grill and remove the original speaker.

2.2.2. connect the JEHNERT-midrange with a speaker cable (1,5 - 4 mm2) Lead the cable to the mount of the crossover in the dashboard (page 9)

2.2.3. insert the midrange with installation installation ring into the original mount so thhat the fastening cover plates on the midrange match the original fastening points. Fasten with original screws.

IMPORTANT:Tweeter-position radiateparallel to the front glas !

75110 VW Bus T 4 - 11 - © JEHNERT SOUND DESIGN

2. midrange and tweeter installation in the dashboard

75110 VW Bus T 4 - 4 - © JEHNERT SOUND DESIGN

Circuit diagram of 2-way crossover / 4x subwoofer

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

WO

OF

ER

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

WO

OF

ER

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

WO

OF

ER

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

H i g h

Pe

rf

or

ma

nce

D E S I G

N

JEHNERT

SoundSound

WO

OF

ER

Sp

ea

ke

rM

AD

E IN

GE

RM

AN

Y

tweeterwoofer

SoundSoundD E S I G N

JEHNERT

midrangeINPUT

3-way crossover circuit

VW BUS T 4

= set of cables supplied w

ith

amplifier

from 200 W

att RM

S / 4 Ohm

recomm

ended power

Page 13: VW BUS T4 - jehnert.de

Removing the grills:The Velcro fasteners stick together very strongly!The grills can be removed anytime by carefully lifting them off.Please, avoid any way of forceful yanking at the grills.It could break!

9.3.

9.2. Our Tip: If the panel cannot be pressed on completely at some points. . .

Cause: the special form at these points and the resulting differences inmaterial cross section of the grill.

Solution: the distance can be levelled out with spacers 3 under theVelcro disc.(Spacers included with the screw kit)

9.1. Precisely align and carefully press grill into the Velcro fasteners.

The Velcro fastener makes a crackling sound when it is closed correctly.

1.1. roll down window completely

1.2. pry out the plastic bolt (A) at the door-innerside and pry out the plastic cap at the door lock (B).

A

B

C

1.3. pry out the plastic cap at the door handle (C) abhebeln and unscrew the 3 cross head screws underneath.

BA

1.4. carefully remove the plastic clips on the door-lining edges and move the door-lining forward away from the inner door metal

1.5. disconnect the original loudspeaker and remove the Bowden pull wire.

1.6. Loosen the screws of the original tray fastening and remove the tray.

C1C2

C3

1 . Disassembly of the door lining

75110 VW Bus T 4 - 3 - © JEHNERT SOUND DESIGN 75110 VW Bus T 4 - 12 - © JEHNERT SOUND DESIGN

9. Installation of the speaker’s grill:

grill

2 self-adhesive Velcro-strip

1 Velcro fastener

3 Washer M4 ø 20 as spacer

doorpanel

Page 14: VW BUS T4 - jehnert.de

Packing unit Check list

door panel, covered (right / left)

Speaker grill, covered (right / left)

tweeter 26 mm

midrange 100 mm Q

Adapter for midrange and tweeter

woofer 160 mm (each mounted on the paneel with 4 sheet metal-screws)

crossover (right / left)

standard cables for subwoofer (right / left)

Hardware bag: flat head screws M 4 x 60

metal screws, 3,9 x 25(for angle fastening)

metal screws, 5,0 x 80

metal screws, 5,0 x 90

sheet metal screws, black 3,9 x 13 (for tweeter mounting)

sheet metal nuts ø 3,9 mm

Hex nut M4

Washer Ø 20mm for metric screws 10x + 4x as spacer for Velcro fastener

Velcro strip à 2,5 cm (reserve)

Preassembled hardware: Velcro fastener plus strips

flat head screws M 4 x 16

flat head screws M 4 x 50

flat head screws M 4 x 30 (right side)

flat head screws M 4 x 40 (left side)

sheet metal screw, black 3,9 x 13 (for woofer)

sheet metal screw, black 3,5 x 13 (for velcro fastener)The product was carefully packed and checked for its completeness. If you find anything missing, damaged ordefective, please notice our guarantee services on the back of these assembly instructions.

Packing list 75110

75110 VW Bus T 4 - 13 - © JEHNERT SOUND DESIGN 75110 VW Bus T 4 - 2 - © JEHNERT SOUND DESIGN

2

2

2

2

2

32

2

2

4

4

8

2

2

4

10

14

4

16

2

2

1

1

32

16

T e c h n i c a l i n f o r m a t i o nEquipment: electric window control

Model/ year: T 4

Insulation: is absolutely necessary ! - see page 8

Note about setting: To obtain optimal stereoscopic sound, all settings on the radio (bass, treble, loudness etc) should be set to zero or neutral.

Recommendedamplifier power : from 2x 200 - 360 Watt RMS / 4 Ohm

Metal cutwork : not necessary

Cut-outs for loudspeaker/ 4 x 144mm (max.outer dimensions subwoofer 165 mm)each side (max.installation depth subwoofer 65 mm)

DIN-Euro-Norm-standard basket ø 6“ made it fit

Sound-System: 3-ways 4 x 160 mm subwoofer/ side

1 x 100 mm midrange / side 1 x 26 mm tweeter / side car-customized crossover network

max.continuous Watt/RMS: 2 x 300/500Watt car specific frequency range: 39-22.000 Hz Total impedance: 4 Ohm

We reserve the right to make technical changes, as well as development.

165mm

Page 15: VW BUS T4 - jehnert.de

Packing list .......................................................................... 2

1. Disassembly of the door lining .............................................. 3

2. Installation midrange and tweeter in the dashboard ................ 4

3. Panel alignment ................................................................... 5

4. Handling of doorlining / Installation door panel ..................... 6

5. speaker cables / Handling of car doors .................................. 7

6. Insulation of the door lining / car doors ................................. 8

7. Installation of the door lining onto the car doors .................... 9

8. Crossover circuit - Speaker connection .................................. 10

Lodspeaker wiring diagram .................................................. 11

9. Installation of the speaker-grills ............................................ 12

Technical Information .......................................................... 13

Service / fault diagnoses ....................................................... 14

Guarantee .......................................................................... 15

page

75110 VW Bus T 4 - 1 - © JEHNERT SOUND DESIGN

C o n t e n t s

Particularly important notes contain the following remarks:

Please follow the installation instructions“step by step”

and check the package contents

Steffen KretzschmarSaddlery / Completion

75110 VW Bus T 4 - 14 - © JEHNERT SOUND DESIGN

Technical questions Hotline: 0049-711-77 97 87-87

We thank you for your support!

Mirko SchwarzDevelopment

It is our pleasure to help you!

Dear customer,

We have taken great care to explain the procedures in our installation instructionsmore detailed and “step by step”.

Your tips and suggestions help us for the future to eliminate uncertainties andmisinterpretation. Therefore, please inform us. what you would like to be improvedor what we should still change.

Marc SitterExport / ServiceMarc Sitter

Export / Service

The following notes serve to help troubleshoot and eliminate faults or malfunctionson your own. If the following measures are not effective, please call us.

What can it be if ... possible cause/ solution

..it doesn’t sound right. wrong polarity on the subwoofers ( page 10) crosover circuit attached wrong ( page 11)

Doorlining and moisture protection foil not cut out ( page 6+9)

amplifier doesn’t have enough power ( page 13)

amplifier connection

...it doesn’t fit correctly. door panel customization ( page 5)

installation of the panels on the door lining (page 6)

.....grills do not hold. observe notes on page 12!

vibrations insulation, see notes on page 8

Self-help and fault diagnosis

The following notes serve to help troubleshoot and eliminate faults or malfunctionson your own. If the following measures are not effective, please call us.

What can it be if ... possible cause/ solution

..it doesn’t sound right. wrong polarity on the subwoofers ( page 10) crosover circuit attached wrong ( page 11)

Doorlining and moisture protection foil not cut out ( page 6+9)

amplifier doesn’t have enough power ( page 13)

amplifier connection

...it doesn’t fit correctly. door panel customization ( page 5)

installation of the panels on the door lining (page 6)

.....grills do not hold. observe notes on page 12!

vibrations insulation, see notes on page 8

Self-help and fault diagnosis

Technical questions: Hotline 00 49 71 58 / 9 56 99-0

Packing list .......................................................................... 2

1. Disassembly of the door lining .............................................. 3

2. Installation midrange and tweeter in the dashboard ................ 4

3. Panel alignment ................................................................... 5

4. Handling of doorlining / Installation door panel ..................... 6

5. speaker cables / Handling of car doors .................................. 7

6. Insulation of the door lining / car doors ................................. 8

7. Installation of the door lining onto the car doors .................... 9

8. Crossover circuit - Speaker connection .................................. 10

Lodspeaker wiring diagram .................................................. 11

9. Installation of the speaker-grills ............................................ 12

Technical Information .......................................................... 13

Service / fault diagnoses ....................................................... 14

Guarantee .......................................................................... 15

page

75110 VW Bus T 4 - 1 - © JEHNERT SOUND DESIGN

C o n t e n t s

Particularly important notes contain the following remarks:

Please follow the installation instructions“step by step”

and check the package contents

Steffen KretzschmarSaddlery / Completion

75110 VW Bus T 4 - 14 - © JEHNERT SOUND DESIGN

Technical questions Hotline: 0049-711-77 97 87-87

We thank you for your support!

Mirko SchwarzDevelopment

It is our pleasure to help you!

Dear customer,

We have taken great care to explain the procedures in our installation instructionsmore detailed and “step by step”.

Your tips and suggestions help us for the future to eliminate uncertainties andmisinterpretation. Therefore, please inform us. what you would like to be improvedor what we should still change.

Marc SitterExport / ServiceMarc Sitter

Export / Service

The following notes serve to help troubleshoot and eliminate faults or malfunctionson your own. If the following measures are not effective, please call us.

What can it be if ... possible cause/ solution

..it doesn’t sound right. wrong polarity on the subwoofers ( page 10) crosover circuit attached wrong ( page 11)

Doorlining and moisture protection foil not cut out ( page 6+9)

amplifier doesn’t have enough power ( page 13)

amplifier connection

...it doesn’t fit correctly. door panel customization ( page 5)

installation of the panels on the door lining (page 6)

.....grills do not hold. observe notes on page 12!

vibrations insulation, see notes on page 8

Self-help and fault diagnosis

The following notes serve to help troubleshoot and eliminate faults or malfunctionson your own. If the following measures are not effective, please call us.

What can it be if ... possible cause/ solution

..it doesn’t sound right. wrong polarity on the subwoofers ( page 10) crosover circuit attached wrong ( page 11)

Doorlining and moisture protection foil not cut out ( page 6+9)

amplifier doesn’t have enough power ( page 13)

amplifier connection

...it doesn’t fit correctly. door panel customization ( page 5)

installation of the panels on the door lining (page 6)

.....grills do not hold. observe notes on page 12!

vibrations insulation, see notes on page 8

Self-help and fault diagnosis

Technical questions: Hotline 00 49 71 58 / 9 56 99-0Technical questions: Hotline 00 49 71 58 / 9 56 99-0

Page 16: VW BUS T4 - jehnert.de

SoundSoundD E S I G N

JEHNERT

VW

BU

S T

4

G u a r a n t e e

2004/by.aj/FH - 15 -

Installation instructions

inst

al.i

nst

r.n

o.

75

11

0FH

05

/04 part-no. 75110

Jehnert Sound Designdevelopment and

production ofCar-Audio-Systems

Heinrich-Hertz-Str. 1170794 Filderstadt

Tel.: 0049-711-77 97 87- 87Fax: 0049-711-77 78 921

e-mail: [email protected]

We grant a manufacturers guarantee of 2 years starting from the date of purchaseof the door panels or sound system from the dealer.

Within this guarantee period to our choice we either repair or replace free ofcharge all defects due to material or workmanship.

Exempt from this guarantee are damages due to improper use, wear and tear ordamages which have to be led back on wear or interventions by third parties.The guarantee does not cover subsequent damages or such defects that onlyinsignificantly impair the value or the usability of the panels/sound system.The guarantee does not cover damages due to external influences.

Panels with additional or wrong assembly drill holes cannot be returned. These are damages to the panel which cannot be repaired again.

Production ofCar-Audio-Systems

Porsche Str. 1570794 Filderstadt

Tel. 00 49 71 58 / 9 56 99-0Fax 00 49 71 58 / 9 56 99-10

e-mail: [email protected]