Auto Manual Resource: 01/23/10

2005-2008 Chevy Cobalt Exhaust System Installation

Prior to installation, be sure your vehicle is parked on a level surface, and the exhaust system is cool. For safety purposes and ease of installation, we urge you to take your vehicle to a qualified service center or muffler installer that employs the use of a lift.

Exhaust System Removal:
1. Measure the exhaust pipe 7-1/2 inches forward of the rear axle and mark a line.
2. Using a saw or chain style pipe cutter, cut the stock system.
3. Using a 15 mm socket remove the two flange nuts.
4. Remove the front hanger from the rubber isolator and remove the front section of the stock exhaust system.
5. Remove the rubber isolator after the axle from both the vehicle and the exhaust system (See Fig. D).
NOTE: Be sure to save all rubber isolators removed from the vehicle. They will be used to install the CORSA Performance exhaust system in later steps.
6. Support the exhaust system, and remove the rubber isolators after
the rear muffler from both the vehicle and the exhaust system.
7. Remove the remaining section of the exhaust system.
8. Install all rubber isolators back onto the vehicle.

CORSA Performance Exhaust System Installation:
1. Remove all exhaust system components from the shipping cartons, including clamps. NOTE: There are three 2-1/2 inch clamps supplied. NOTE: Apply the anti-seize lubricant (supplied) to the threads ONLY of all the TORCA band clamps and flange bolts. Failure to follow this procedure can cause nuts to seize on clamps and potentially damage threads.
After applying anti-seize lubricant, be sure to thoroughly clean hands as lubricant will tarnish stainless steel.
2. Locate the front muffler assembly, flange gasket, nuts and bolts
3. Place the flange gasket over the flange after the catalytic converter, and using a 15mm socket and a 5/16” allen wrench install the front muffler assembly. Tighten the flange bolts to 40 ft-lbs (See Fig. G).
4. Locate the intermediate pipe assembly and place a TORCA clamp on the inlet.

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2007 Cadillac Escalade 6.2L AWD 4dr Cat-Back Single Exhaust Installation Instructions

SUGGESTED TOOLS: 1/2″, 9/16″, 15mm wrenches & sockets, WD-40, hacksaw, jack stands

1. Disconnect the negative battery cable before removal of OEM exhaust. This will allow the computer to reset and recognize the new exhaust. Lay out the exhaust on the floor so it looks like the drawing and compare parts with manual.
2. To remove the stock exhaust, unbolt it at the 2-bolt flange located in front of the muffler. Disengage the welded hangers using WD-40 from the OEM rubber grommets. Do not damage stock nuts and bolts or remove the rubber grommets as you will re-use them to mount your new system. Now, cut off tailpipe and remove exhaust.
3. Install head pipe #A onto your existing stock flange and attach using the stock hardware. DO NOT TIGHTEN. Insert welded hanger into rubber grommet.
4. Install muffler #B onto head pipe 1―”-2” with the louvers facing towards the converter. Use a jack stand to support the muffler. Use clamp #F to secure the muffler to the headpipe. DO NOT TIGHTEN. Muffler inlet is looking into louvers.
6. Install tailpipe #C into muffler 1―-2” and secure with clamp #F. DO NOT TIGHTEN. Insert welded hanger into rubber grommet.
7. Install exit pipe #D into the tailpipe 1―-2” and secure with clamp #F. DO NOT TIGHTEN. Rotate pipe to best suit your vehicle.
8. Install stainless steel tip. Clamp down. When you have everything in place, firmly tighten all bolts and clamps down securely. Use stainless steel cleaner and a Scotch Brite pad weekly to prevent tip from discoloration. Inspect all fasteners after 25-50 miles of operation and re-tighten as necessary.

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1996-00 Chevrolet, GMC Truck & SUV 5.7L V-8 ECONOAID Throttle Body Plate Instructions

1. Disconnect the negative battery cable! Remove the plastic wing nut on the air intake hat behind the throttlebody. Loosen the hose clamp that secures the flexible intake tube to the throttle body hat. Disconnect the crankcase breather hose. Roll the air intake hat towards the front of the vehicle to remove it, and set it aside.
2. A.) Remove the three bolts that secure the throttlebody to the intake manifold. B.) Remove the bolt that secures the throttle cable bracket to the throttlebody. C.) Lift up the tabs, and disconnect the two wiring harnesses of the drivers side of the throttlebody. Lift the throttlebody off of the intake manifold and set it to the side.
3. Install the ECONOAID Plate against the intake manifold with the logo facing the throttlebody. Next install the supplied gasket between the plate and the throttlebody.
4. Reinstall the throttlebody onto the intake manifold and tighten all three bolts securely. Reconnect the two wiring harnesses. Reinstall the bolt thru the throttle cable bracket and into the throttlebody. Before starting the engine, open and close the throttlebody to make sure there are no obstructions.
5. Reinstall the intake hat and tighten the wing nut. Reconnect the crankcase breather hose. Reconnect the intake tube and tighten the clamp.
6. Double check your work. Make sure there is no foreign material in the intake tract. Make sure all clamps, hoses, nuts, and bolts are secure. Reconnect the negative battery cable.

Get pdf 1996-00 Chevrolet, GMC Truck & SUV 5.7L V-8 ECONOAID Throttle Body Plate Instructions

2007-2008 Chevy 4.8, 5.3, 6.0 Silverado/Sierra VPI Cold Air Performance Intake System Installation

Installation Instructions:
1. Disconnect negative battery cable. Then loosen all three factory hose clamps located at the Mass Air Flow (MAF) meter and both factory intake tube.
2. Remove black cover on throttle body by pulling up and sliding towards front of truck. It is held by two grommets. Gently pry the radiator hose bracket from the factory intake tube assembly and remove the tube from the vehicle. A flat head screwdriver may be used.
3. Remove the factory air filter base and lid as an assembly. There are no bolts, just friction mounts, so just pull straight up on the air filter base to remove. Then remove the plate that held the base and lid. There are (5) 10mm bolts to unscrew to remove the plate. After everything is removed it should look like the picture above.
4. Install the black plastic filter adapter ring using the (3)1/4 20 Screws and washers provided.
5. Position the VPI Intake Box over the inner fender cavity and secure with the (3) factory bolts you removed from the bottom plate.
6. Slide the factory MAF meter back onto the black plastic filter adapter ring. Important: Factory clamp/rubber bushing must be in place on the inlet to the MAF meter.
7. Install the hump hose provided onto the VPI Intake Tube with the supplied hose clamps.
Note: Slide the hump hose all the way onto the end of the tube.
8. Insert grommet and fitting into hole on VPI tube. Connect intake tube (with the now attached hump hose) to the MAF. Tighten clamps. Connect 3/8 hose from VPI tube to valve cover.
Note: It may be necessary to lubricate fitting with water to slide the breather hose on.
9. Connect intake tube end into the throttle body using factory GM coupler that is provided.
Final Steps
Check for any foreign objects or debris in the intake path. Double check your work, to make sure all nuts, bolts and clamps are fastened securely. Reconnect the negative battery cable.

Get pdf 2007-2008 Chevy 4.8, 5.3, 6.0 Silverado/Sierra VPI Cold Air Performance Intake System Installation

99-02 Full Size Chevy / 99-04 GMC Hoods Installation

STEP 1: Adjust hood until proper alignment with matching panels is achieved. There are two rubber bumpers located in the inner fender jam, they will need to be removed.
STEP 2: Adjust primary latch until it fits into the latch bar on the hood without hitting any perimeter edges of the opening. Make sure when the hood is closed you can hear the latch “click” onto the hood.
STEP 3: After you here it click, test it to be sure it’s working properly by grabbing the front edge of the hood and slowly pulling upward with a steady even pressure. If the hood opens it’s not adjusted properly; repeat STEP 2 until hood cannot be pulled open after it’s closed.
STEP 4: To ensure the safety catch is working properly, close the hood, pull the hood release from inside the car and the hood will partially open. Slowly pull upward on the hood and jiggle it at the same time. If it opens without pulling the safety catch lever then it needs to be readjusted. The safety catch prevents the hood from opening in the event the primary latch fails.
STEP 5: Locate the hood stoppers located on each side of the radiator support. Adjust upward until they apply a small amount of pressure to the underside of the hood when it is closed. This will prevent the hood from shaking or rocking.

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2001-2007 Chevy/GMC Duramax Diesel Installation Instructions

Pump mounting
We have found the best location if using a tank in the bed is in this location. Drill 4 holes
Remove Intake
On LMM LBZ
Loosen all bolts and nuts labeled with red arrows
On LLY
Loosen 6, 12mm bolts/nuts on the intake manifold. Remove the intake manifold. (Note: it will not be easy to get at all the bolts and remove the manifold, but it can be done just moving the cables out of the way) Be careful not to lose the 2 EGR gaskets and 1 intake manifold gasket.
Loosen BOTH ring clamps on flexible boost tube connector, pull the boost tube down and backwards with the intention of separating the boost tube from the intake manifold at the top most joint.
Nozzles
Take the intake and put on a flat surface and Drill 11/32 hole on the flat portion of the intake that faces towards the firewall when installed in the truck. Now run a 1/8npt-27 tap thru the drilled holes.
Then Thread Nozzles into intake. These should tighten down till the O-ring just starts to sit flat on intake don’t over tighten to the point the O-ring starts to push out.

Reinstall Intake
Tighten all bolts and nuts labeled with red arrows
Map Sensor Wire
DevilsOwn Progressive Controller injects water methanol according to MAP sensor signal. On the Duramax the MAP sensor signal wire is a Lt. Green and is located as the center pin of the three pin connector. Use one of the supplied Posi-Tap connectors to tap onto this the MAP SIGNAL wire from the controller harness. If you are running any type of power module, make sure you tap onto the signal wire before the power module.

Get pdf 2001-2007 Chevy/GMC Duramax Diesel Installation Instructions

KD-NX5000 HDD Navigation/DVD Receiver Instructions

Hard Disk Drive (HDD) Installation
This unit has a built-in HDD, which is a device to read minute magnetic changes. The inside of the device is precision components, requiring you to notice the following when installing the unit:
Install the unit at a place where the following conditions are satisfied:
• Dry and neither too hot nor too cold— between 5°C and 35°C. If the temperature is too low, the HDD will not work. Wait until the temperature in thecar becomes normal before operating the unit.
• At an altitude between –300 m below sea level and +3000 m above sea level.
• With adequate ventilation to prevent internal heat buildup in the unit.

Before using HDD
While the unit is turned on, the hard disk is constantly rotating at a high speed. This requires you to notice the following:
• DO NOT impart vibration or shock.
• DO NOT allow anything having strong magnetism or emitting strong electromagnetic waves (mobile phones, etc.) near the unit.
• DO NOT disconnect the power cords from the car battery when the unit is turned on. Failure in following the above cautions may damage the HDD (the stored data will be lost and be never restored)

Calibration
Before using the Navigation System first time, it is required to calibrate the Navigation System.
• After deleting the calibration data (☞ [46] Reset Calibration) or changing the installation angle (☞ [46] Installation Angle), calibration is also required.
1. Display the map screen.
2. Display the detail screen and check the connections.

GPS Antenna
• OK ] Connection is OK. ([5]: number of the GPS satellites whose signal is detected.)
• NG ] Aerial is disconnected or short-circuited.

Speed Signal
Drive the car for a while.
• If the number increases as you speed up the car, connection is OK. Parking Brake Step on the brake pedal, then disengage and engage the parking brake repeatedly.
• If Off appears when disengaged and On appears when engaged, connection is OK. If the result is not good, check the connection.
• You can see detailed information on the items of Sensor Status in Information.
3. After confirming all the above connections, drive the car to start calibration.
• This process can take five minutes or more depending on the average speed driven.
• A certain speed (greater than 40 km/h) is required for calibration.
• Calibration time differs among the cars.
• During calibrating, you can use the AV functions of the unit (you can listen to the music, etc.)
• If you turn off the ignition switch, calibration is temporarily stopped. When it is turned on, calibration will restart. Once calibration is finished, the arrowhead icon turns red and the current position information
appears instead of Calibrating…. Learning Lv. (maximum level is 4) reaches 1 after calibration finished.
Navigation (functions such as guidance or route simulation) cannot be used until calibration is complete.

Get pdf KD-NX5000 HDD Navigation/DVD Receiver Instructions

2002 Chevy Trailblazer / GMC Envoy Air Intake Installation Instructions

These instructions will take you through the installation of your new air intake system for your vehicle. We always recommend that you keep your stock air intake system in storage in case you might need it later.
Kit includes: air filter, air intake tube, bracket, (2) 3” hose clamps, red connecting hose and rubber grommet.
Tools required: Phillips head screwdriver and 5/16” nut driver.

1) Removing stock air intake system
Remove the 3 screws holding the air box with a phillips head screwdriver (fig.1, 2, 3). NOTE: You will need one of these screws later in the installation.
Remove the air box extender (fig.4) and the oxygen sensor (fig.5).
Loosen stock hose clamp and remove entire intake tube and filter (fig.6)
2) Installing your new intake tube
Stretch the red connecting hose over throttle body outlet and afix hose clamp over it (fig.7).
Fix rubber grommet into intake tube (fig.8).
Place other hose clamp on red connecting hose and install new air intake (fig.9).
Put oxygen sensor into intake tube at rubber grommet.
3) Installing the air filter
Loosen the hose clamp at the base of the air filter and slide onto end of the intake tube (fig.10). Do not tighten down the hose clamp yet.
Slide the curved end of the bracket between the hose clamp and the filter base (fig.11). Line the hole on the other end of the bracket with the hole the original air box was secured by. Use one of the original screws to secure your new bracket.

Get pdf 2002 Trailblazer / Envoy CGS Air Intake Installation Instructions

2004-05 GMC CANYON Billet Grilles Installation

1. Remove the factory grille shell from vehicle, by releasing the (4) key hole tabs across the top of grille shell. Then there are (2) clips behind the parking lights on the driver & passenger side of grille shell, release by pulling straight out on shell. Then release (3) clips along the bottom of grille shell, by pulling straight out on shell.
2. After grille shell is removed place shell face up on a protective surface, such as a blanket or rubber mat.
Next you will be removing the center section of the factory grille shell, using a cut-off wheel or hack saw. Trim all vertical & horizontal plastic holding center in place.
3. Lay grille shell face down, and using cut-off wheel or hack saw trim the remaining plastic. Using the Red Line as a guide for trimming (Fig 3A). Next sand edge smooth using a sanding block. (Fig 3B) Shows after Trim & Sand.
4. Next attach the Long “L” brackets to top of billet grille as shown. The long end attaches to billet grille with U-Clips and #8 x 5/8” Phil Pan head screw.
5. Next attach the Short “L” brackets to the bottom of billet grille as shown. The long end attaches to billet grille with U-Clips and #8 x 5/8” Phil Pan head screw.
6. Place billet grille into shell from the front and center in opening. The bottom of billet grille with be flush with black trim ring on shell. Then clamp billet grille in place using a pair of vice grips with tape on the jaws to protect billet grille.
7. Next mark the locations of the top and bottom brackets where they meet the grille shell. Then using a 1/8” drill bit, drill hole in each marked location. Then attach using U-Clips and #8 x 5/8” phil pan head screw.

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GMC Sierra/Chevrolet Silverado 6.6L Diesel LB7 True Flow System Installation

Please read this instruction sheet BEFORE proceeding. Excess oil must be removed from filter before installation. Blot using paper towels on front and backside of filter until excess oil is removed.
1. Using a socket or an open-end wrench, disconnect the negative terminal connection on the vehicle battery.
2. Remove the black muffler box located on top of the throttle body that connects to the factory rubber / plastic flex hose. You will need a #30 Torx bit.
3. Remove the factory rubber / plastic flex hose that connects the throttle body to the air filter box.
4. Using a Phillips screw driver, remove the air box lid. Remove the factory paper air filter and replace with the supplied True Flow air filter.
5. Install the red 4’’ x 3-1/2’’ silicone coupler and appropriate clamps to the air filter box outlet. This coupler is an extremely snug fit and will require the use of soapy water applied to the inside of the coupler to ease installation. Make sure coupler is aligned straight with the air filter box outlet then gradually slip the coupler on by applying pressure to multiple points around the coupler until it is fully installed. You may want to unplug Mass Air Flow sensor and remove air box lid to install coupler at a work bench.
6. Slip the 3-1/2’’ x 3-1/2’’ coupler and appropriate clamps over the throttle body.
7. Slide the black True Flow tube into the coupler. The tube will only fit one way. Adjust the tube evenly between the couplers.
8. Once you have the ends of the air tube in both red couplers, make sure the clamps are positioned over the first ―” of the coupler so when tightened down, they apply pressure against the metal tube now inside each end of the coupler.
9. After alignment of the clamps, slowly tighten each clamp down using a standard screw driver and tighten them by hand until it becomes difficult to turn any further.
10. Stop and check all fittings and connections on last time. Now, Put the cable back on the battery and tighten down and make sure it’s not loose.
11. Restart your vehicle and the ECM will reset properly and you should have no check engine light coming on inside the vehicle. If you do, repeat Steps 1 and 10 over again and then Step 11.
12. Place the C.A.R.B. label on or near the True Flow system in the engine compartment.
13. ENJOY!

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GM Radio Replacement Interface for GMLAN Vehicles Without OnStarо

The GMCOL29 allows aftermarket radio installation without retention of the factory radio. The interface replicates all factory warning chimes, audible turn signal indicators and provides a data bus generated 12 volt accessory output that acts just as GM’s R.A.P. (Retained Accessory Power) system did prior to radio removal. R.A.P. keeps the radio powered after the key is off, until the driver door is opened or a 10 minute timer ends, whichever comes first. The GMCOL29 also provides a SWC (Steering Wheel Control) output wire at the interface. By using this interface, the Parking Assist System will receive a “healthy” system status and the Rear Seat Audio controls will also be available for use (if equipped).

Installation:
If the Boseо Audio system is being used, connect the GMCOL29’s RCA inputs to the aftermarket radios pre-amp output. The audio level will vary depending on the new radios pre-amp output voltage (2-4 volts is recommended). If the Boseо Audio system is not used or present, cut the RCA inputs off and connect the new radios speaker outputs to the remaining wire. If the vehicle and the interface both chime, move the chime switch to the off position. The other wire connections are as follows:
• Yellow - 12 Volt Constant Voltage
• Black - Ground
• Red - 12 Volt R.A.P Voltage (1 AMP max)
• Blue/White - Antenna turn on, Amplifier turn on, and RSE turn on (if equipped)
• Orange - Dimmer/Illumination
• Lt. Green - SWC Output Wire
Using the SWC Output wire - Connect the SWC (green) output wire to a Peripheral PESWI interface. Use the green PESWI interface wire and program the PESWI interface for version 2. Follow ONLY the interface programming instructions included with the PESWI interface. Do not cut the Brown loop. (SWC interface sold separately.

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99-02 GMC Sierra Truck & 2000-05 Yukon & Yukon XL Air Dam Installation Instructions CK580-S/CK580-T

REMOVING FACTORYAIR DAM
1. To remove factory Air Dam, use a 6” long flat blade screwdriver. The rivets are accessed through the bottom of the bumper behind the factory Air Dam.
2. It will be necessary to remove the factory driving lights by removing the two bolts that hold the plastic light brackets to the bumper. Also remove the nut clips from the bumper.
3. Insert the screwdriver blade into the rivet head slots and twist screwdriver to force rivet inserts downward. Once rivet inserts are 1/4” to 1/2” down, grab with fingers or pliers and pull down, completely removing inserts.
4. After all rivets and lights are removed, use the screwdriver from the front side of Air Dam and pry down on the Air Dam to remove it from the bumper.
5. Next remove the plastic rivet clips from the bottom of the bumper by squeezing the clips and pulling down.

YOU MUST REMOVE TOW HOOKS TO MOUNTAIR DAM
1. To remove the tow hooks, remove the 4 - 15mm hex head bolts that hold the bumper to the frame brackets; two are at the outside of the bumper bottom with the bolt heads facing down and shaft threading up; the other two are on the inside of the frame rails with the bolt head facing up and the shaft threading down into a hex head frame clip 2. Using an 18mm wrench or socket, remove the 4 - 18mm hex head bolts that screw upward into each tow hook.
3. Using an 18mm wrench and socket, remove the nut from the long bolt that goes through the frame and tow hook from side to side.
4. Due to the bumper design, the long bolt head will hit the bumper when being removed. Slide the tow hook bolt outward until the bolt head contacts the bumper curve.
IMPORTANT: SLIDE THE WASHER THAT IS ON THE BOLT BACK TOWARD THE FRAME.
5. Then using a large screwdriver or medium size pry bar, stick the end of the prying device into one of the square holes closest to the bottom of the bumper curve. Pry the bumper outward just enough so that the bolt head will clear the edge of the bumper - then remove the bolt. BE CAREFUL NOT TO BEND THE BOTTOM FLANGE OF THE BUMPER.
6. Once the tow hooks are removed, replace the 15mm bolts and proceed with Air Dam installation.

Get pdf 99-02 GMC Sierra Truck & 2000-05 Yukon & Yukon XL Air Dam Installation Instructions CK580-S/CK580-T

Stake Pocket Pop-Up Installation Instructions

1. Read and understand these instructions before proceeding. If you drop a screw down in some stake pocket holes it is difficult to retrieve. Some installers prefer to apply masking tape around the stake pocket holes to prevent scratches. Remove the tape before tightening the assembly screws.
2. Select the correct stake pocket insert. The flat model is used for the 88-98 Chevy & GMC models. All other trucks use the insert with the bent flanges. The bent flange style should be oriented with the bent wings pointing up like this: [__________]
3. Slide the rubber gasket, then insert, onto the Stake Pocket Pop-Up to dry fit the pieces together. Line up the holes in all the parts. You must understand what is the front and back orientation of the insert to install the parts correctly.
4. Place the correct insert in the stake pocket hole. Use strips of tape or short lengths of thin wire to hold it up and in place.
5. Slide the main Stake Pocket Pop-Up piece with the rubber gasket installed through the hole in the insert.
6. Start 2 of the provided screws through the Stake Pocket Pop-Up, gasket, and into the insert.
7. Remove the tape or wire used to hold the insert.
8. Start the other 2 screws through the Stake Pocket Pop-Up, gasket, and into the insert.
9. Pull the assembly up so the insert is centered in the stake pocket hole, and alternately tighten opposing screws until the assembly is pulled up but not tight.
10. Tighten the other 2 screws until they are flush with the top of the Stake Pocket Pop-Up.
11. Tighten all 4 screws, being careful to not distort any vehicle sheet metal.
To release the Stake Pocket Pop-Up, use your thumb, finger, or a coin in the slot to twist the center ¼ turn in either direction. To close the Stake Pocket Pop-Up, push the center piece back down into the hole until it is flush then rotate ¼ turn in either direction.

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2003 GMC/Chevrolet Vehicles with DRL Running Lights Carton 07400 Installation Instructions

Mounting the Meyer Daytime Running Lights:
1. Connect the 07104 Adapter Kit as per Nite Saber Instruction sheet (Form 1-757) Installation #4 (Installation of adapter set).
2. Turn on Vehicle and verify operations of the Vehicle Headlight, Daytime Running Lights and Snow Plow lamps. Replace and repair any defective parts, switches, etc. before installing the Daytime Running Light Module. NOTE: To test Daytime Running Light on Vehicle, make sure vehicle is outside in Daytime condition. The 99 & later Chevy is equipped with a photo sensor and will not operate under artificial light.
3. The Meyer Daytime Running Light (DRL) is mounted in the engine compartment close to the battery and near one of the front headlamps and parking lamps. When a location is found, make a mark with a pencil on the inside fender wall of the vehicle through the mounting tab of the DRL module. Drill two 1/8” holes on the marks and mount the unit with two #10 gauge screws provided.

Wire connections:
The ground wire connection is one of the most important connections to be done in the installation and must be done first. The black colored wire is the ground wire and must be connected to metal chassis that provides a path back to battery negative. Check with an ohmmeter if possible to insure it is properly grounded.

NOTE: DO NOT CONNECT THE WIRE HARNESS TO THE MODULE UNTIL ALL NECESSARY CONNECTION(S) ARE MADE.
1. Connect the black wire (Position G) to a metal surface that is clean of dirt, grease and paint. Drill a 1/8” hole and using the #10 screw provided, securely fastened the terminal of the black ground wire.
2. Route the White wire (Position B) to one HCM module (Refer to Form 1-757 item #3). Using the tap splice connector provided, connect the white wire to the white wire on cable “C”. Refer to form 1-757 (Item #5). NOTE: Cable “C” is connected to connector “C” Yellow on the HCM Module.
3. Route the White wire (Position E) to the other HCM module (Refer to Form 1-757 item #3). Using the tap splice connector provided, connect the white wire to the white wire on cable “C”. Refer to form 1-757 (Item #5). NOTE: Cable “C” is connected to connector “C” Yellow on the HCM Module.
4. Route the Blue wire (Position F) to one HCM module (Refer to Form 1-757 item #3). Using the tap splice connector provided, connect the blue wire to the blue wire on cable “C”. Refer to form 1-757 (Item #5). NOTE: Cable “C” is connected to connector “C” Yellow on the HCM Module.
5. Route the Blue wire (Position H) to the other HCM module (Refer to Form 1-757 item #3). Using the tap splice connector provided, connect the blue wire to the blue wire on cable “C”. Refer to form 1-757 (Item #5).
NOTE: Cable “C” is connected to connector “C” Yellow on the HCM Module.
6. Connect the Red wire to the positive terminal of the battery.

Test Procedure:
Ensure that the following connections have been made:
1. Black wire secure to ground
2. White wire to Cable “C” white with (Item 5) (Refer to Form 1-757)
3. White wire to other Cable “C” white wire
4. Blue wire to Cable “C” blue wire
5. Blue wire to other Cable “C” blue wire
6. Red wire to positive terminal on Battery.
7. Touch the end of the Green Wire to the positive terminal of the battery. The Snow plow lamps low beam should illuminate at low intensity. Remove the green wire connection to the battery.

The snow plow lamps low beam should shut off.
NOTE: To test Daytime Running Light on Vehicle, make sure vehicle is outside in Daytime condition. The 2003 Chevy is equipped with a photo sensor and will not operate under artificial light.
NOTE: It may be necessary to strip and bare a small portion of the insulation from the end of the green wire to insure good contact. If lights do not turn on, refer to the trouble shooting index.
NOTE: In most cases when the unit does not work as indicated, it is a poor wire connection. If all lights work, carry on with the final connection of the green wire.
Final Wire Connection:
Locate the OEM Daytime Running Light Lamp. Route the Green (Position D) wire to the DRL lamp and connect it to the positive wire of the OEM lamp (Dark Blue Wire) using the Tap Splice connector provided.

Get pdf 2003 GMC and Chevrolet Vehicles with DRL Running Lights Carton 07400 Installation Instructions

2003 Chevrolet/GMC 2500HD RECON 3-Piece Cab Roof Light Installation

This document covers the installation of RECON Truck Accessories 3-Piece running lights on a 2003 Chevrolet/GMC Silverado/Sierra 2500 HD. RECON 3-piece Chevy/GMC Cab Roof Light Kit Boasts The Following:
Provides Maximum Visibility
Meets S.A.E. specifications
Adapts to Curved and Flat Roofs
Replaceable 194-Style Bulbs
Kit includes 2 Corner Clearance Lights and 1 Three Lamp Cluster Center Marker Light
Complete Wiring Harness with Quick Wire Connectors
Great Retail-Friendly Packaging
All Necessary Hardware

The light kit comes with everything required to install, except it is also recommended that you apply a little silicone/sealant to ensure a lasting seal around the holes & wires.

The installation takes approximately 2 to 3 hours and can be broken down into 5 main steps:
1. Drop front part of headliner
2. Measure/Mark holes for lights
3. Mount Lights
4. Wire Lights
5. Re-assembly

Drop Headliner
Remove sun visor assemblies and sun visor clamp (Torx 15 & 20 required)
Disengage passenger side grab handle. Insert small flat screwdriver to pull out covers/lock mechanism then pull out on handle until you feel it disengage. There is no need to remove handle from headliner.
Disengage DS and PS pillar covers. Pull out at top and away from pillar. Lower panel(s) down so you can drop headliner about 4-6”.
Remove overhead console. Remove front screw. Slide console forward a little and pull down in rear as is a clamp on each side that locks it into the overhead. Disconnect On-Star speaker plug (if equipped) and map light plug. Remove console. At this point you should be able to pull the front part of the headliner down around the front of the windshield. It will only drop about 2” to 3” which should be enough to carefully reach the wires.

Mount Lights
The side marker lights require 2 holes and the center light 5 holes IIRC. Take your time and measure everything twice to make sure you don’t drill any extra holes. You only have one chance.

Side lights:
On driver and passenger side, it is 4 1/4 inches from near edge of black rubber door rubber gasket to the near edge (side) of the roof marker lamp gasket 4 1/8” from near edge of black rubber windshield gasket to front edge of the roof marker lamp gasket

Center Light:
3 1/8 from near edge of black rubber windshield gasket to near edge of the center roof marker lamp gasket. Make sure you measure across to find center of roof and center light accordingly. IIRC, center is around 27 ž” measuring of the windshield top corner moldings. Place the lights at the approximate locations and place masking tape on roof so you can mark/drill without damaging the paint. It’s best to start with the center light so you’re not leaning over the outside lights during the installation process.
Measure all lights and mark holes. Once the lights are in place and measured, use a sharp tipped round scribe to mark the holes as you will need to place it down thru the light holes which are about 1” tall. This made marks on my tape which are visible once the lights are removed.

Get pdf 2003 Chevrolet/GMC 2500HD RECON 3-Piece Cab Roof Light Installation

Jet Trax Watercraft and Motorcycle Mounting Plate Installation Instructions

These instructions are to insure proper installation, which will enhance the safety and reliability of your Jet Trax System. The Jet Trax System is designed to provide years of dependable service without undue maintenance cost or operations problems. By following these step-by-step instructions, your Jet Trax System will become a secure and reliable transporting and loading device.

STEP 1
Read these instructions completely before starting the installation. Pay particular attention to all of the safety notes.

STEP 2
Installation of the Universal Mounting Plate
This mounting plate can be used on all Jet Trax systems. The basic installation consists of:
Bolting down the furnished mounting plate
Bolting the Jet Trax System to the plate.
Bolting down the rear of the Jet Trax system

You will find a ―” X 3” X 48” flat bar packed with your system. This bar has smooth holes drilled through it and also has threaded holes to accept the 2 ž “ long bolts found in the hardware bag located in the battery box.
A. Slide the Jet Trax unit into the truck bed, and close the tail gate, making sure that the Jet Trax unit has approximately ―” clearance in the back with the tail gate closed. Scribe a mark along the front of the 3” channel at the front of the truck bed. This will show you where the universal mounting plate is to be mounted. Center the universal mounting plate in the truck bed along the scribe line.
a. On a FORD, use the holes outside of the tapped holes. Drill two 9/16” holes through the bed and secure with 2 ―” bolts and nuts provided. A 3” square plate is provided to be used as a large washer and add structural support under the bed of the truck.
b. On a DODGE, CHEVROLET, or GMC truck, two holes must be drilled. Choose two holes in the plate that are between the tapped holes. Mark the hole location and drill a 9/16” hole through the bed and bed cross members and secure with the 5 ―” bolts and nuts provided.
B. Once the mounting plate is installed, slide the Jet Trax unit into the truck bed, until the 3” channel iron on the front of the Jet Trax straddles the mounting plate. Put the 2 ž” bolts into the lock washers and flat washers, then through the oval holes in the Jet Trax base. The bolts will go into the threaded holes in the mounting plate. Tighten securely. Check all mounting hardware periodically.

Get pdf Jet Trax Watercraft and Motorcycle Mounting Plate Installation Instructions

07-08 GMC Sierra Denali 1500, 6.2L, 2wd Cat-Back Stainless Dual Extreme Exhaust Instructions

When installing this exhaust system make sure to use proper safety precautions. Use jack stands when working under the vehicle, set parking brake, block tires and use safety glasses and gloves. Allow exhaust to cool before attempting installation. Severe injury or burns could occur if safety measures are not taken.
SUGGESTED TOOLS: 1/2″, 9/16″, 15mm wrenches & sockets, WD-40, hacksaw, jack stands

1. Disconnect the negative battery cable before removal of OEM exhaust. This will allow the computer to reset and recognize the new exhaust. Lay out the exhaust on the floor so it looks like the drawing and compare parts with manual.
2. Remove the stock exhaust by unbolting it at the 2-bolt flange located in front of the muffler. Disengage the welded hangers from the OEM rubber grommets. Use WD-40 to aid in this process. Do not damage stock nuts and bolts or remove the rubber grommets as you will re-use them to mount your new system. Now, cut off tailpipe and remove system.
3. Install headpipe #A onto your existing stock flange and secure using the stock hardware. Do not tighten. Insert welded hanger into rubber grommet.
4. Install muffler #B onto headpipe 1―”-2” with the louvers facing towards the converter. Use a jack stand to support the muffler. Use clamp #G to secure the muffler to the headpipe. Do not tighten. Muffler inlet is looking into the louvers.
5. Next, remove your spare tire. Then install passenger side tailpipe hanger #J. You will see a 1―” hole in the frame. Attach hanger to this hole and re-install factory grommet on hanger.
6. Slide passenger side tailpipe #C into muffler 1.5-2”. Use clamp #H to secure. Do not tighten. Insert welded hangers into rubber grommets.
7. Slide driver side tailpipe #D into muffler 1―”-2” and secure with clamp #F. Do not tighten. Insert welded hangers into rubber grommets.
8. Now install driver side tailpipe hanger. Use same 1―” hole on the frame, but on the driver side. Install rubber grommet on hanger. Then install hanger from pipe into rubber grommet.
9. Slide each exit pipe #E onto the each tailpipe 1.5-2” and secure with clamp #H. Do not tighten. Rotate exit pipes to best suit your vehicle. It is best to adjust these pipes with the tips already on the pipes. That way you can make sure there is proper clearance.

Get pdf 07-08 GMC Sierra Denali 1500, 6.2L, 2wd Cat-Back Stainless Dual Extreme Exhaust Instructionsg

2000-2007 Classic Chevy/GMC 2WD C1500 P/U 7″ Performance Suspension System

INSTRUCTIONS:
1. Disconnect the negative terminal on the battery. With the truck on level ground measure the trucks ride height from all four corners. Record the heights for use in the installation of the kit.
2. Jack up the front end of the truck and support the frame rails with jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE! Remove the front tires.
3. On both sides of the truck, remove the hardware securing the brake line to the spindle, discard hardware. Remove the bolts attaching the brake caliper to the spindle, save hardware. Remove the caliper and tie is up out of the way. DO NOT ALLOW THE CALIPER TO HANG BY THE BRAKE LINE! Remove the brake rotor. Remove the front sway bar end links and discard. Also, disconnect the ABS wire from the frame.
4. On the driver side of the vehicle support the lower control arm (LCA) with a jack and remove the front shock and discard, save hardware from lower shock mount and discard upper shock hardware. Remove the nut from the end of the tie rod and separate the tie rod from the spindle by hitting the end of the steering knuckle with a hammer, as shown above, DO NOT HIT THE THREADS ON THE TIE ROD END. Save hardware. SEE PHOTO IN NEXT COLUMN.
5. Locate the three factory bolts on the back side of the spindle attaching the bearing assembly to the spindle. Remove bolts and bearing assembly and save.
6. Remove the nut holding the upper ball joint to the spindle. If the ball joint shaft spins inside the spindle, insert an allen wrench in the bottom of the ball joint and loosen the nut with a wrench. Do not remove nut at this time
7. Separate the ball joint from the spindle by hitting the side of the spindle with a hammer. DO NOT HIT THE THREADS ON THE BALL JOINT. Remove the ball joint nut from ball joint than remove upper ball joint from the spindle and save hardware. Remove the nut from the lower ball joint and separate the spindle from the lower ball joint, you may need to hit the side of the spindle with a hammer to free the lower ball joint from the spindle, save nut. BE SURE NOT TO HIT THE THREADS OF THE BALL JOINT. Discard factory spindle.
8. Slowly lower the floor jack supporting the lower control arm to release the coil spring. EXERCISE EXTREME CAUTION WHEN WORKING WITH COIL SPRINGS UNDER LOAD! Set the coil spring aside and make sure to remove the upper and lower spring insulators. DO NOT DISCARD THE COIL INSULATORS, THEY WILL BE REINSTALLED ON THE NEW COILS.
9. Remove the factory lower control arms from the truck. Save the factory hardware as you will reuse it during installation.
10. Locate the factory lower control arm bump stop on the frame. Remove and discard.
11. Repeat steps three through nine on the passenger side of the vehicle at this time.
12. If equipped, remove the factory strut tubes and discard.

Get pdf 2000-2007 Classic Chevy/GMC 2WD C1500 P/U 7″ Performance Suspension System

2007-2008 Chevrolet & GMC Truck with a 5.3L, 6.0L & 6.2L V8 Mac Performance Instructions

1. Start by disconnecting the wire harness from the MAF sensor as shown.
2. Remove the cover from the intake manifold by lifting it up and then pulling it out as shown.
3. Unplug the vent air tube from the stock air silencer as shown.
4. Remove the clip holding the radiator hose to the stock air tube as shown.
5. Loosen the hose clamp on the stock air tube at the MAF meter and the throttle body and remove the stock air tube as shown.
6. Remove the cover of the stock air box as shown and set aside.
7. Pull up on the stock air box and remove it form the vehicle as shown.
8. Using a 10mm socket and ratchet remove the bolts (4) that hold the stock plate in place and remove as shown.
9. Install the MAC velocity adaptor to the MAC air dam as shown using the hardware provided.
10. Install the MAC air dam into the stock location as shown using the stock hardware.
11. Loosen the hose clamp that holds the MAF meter to the stock air box and remove as shown.
12. Remove the hose clamp and the rubber mount as shown from the MAF meter.
13. Install the straight silicone hose to the velocity adaptor and to the MAF meter and tighten as shown.
14. Install the 30° silicone hose to the MAF meter as shown. Note: Do not tighten the hose clamp.
15. Install the 70° silicone elbow to the MAC air tube as shown. Note: Do not tighten the hose clamp.
16. Install the MAC air tube to the throttle body and to the silicone hose on the MAF meter as shown.
17. Once the MAC air tube is aligned tighten the hose clamps on the air tube as shown.
18. Attach the clip on the upper radiator hose to the bracket on the MAC air tube as shown.
19. Install the vent air tube provided in the kit to the stock air tube as shown.
20. Install the vent air tube to the fitting on the MAC air tube as shown.

Get pdf 2007-2008 Chevrolet & GMC Truck with a 5.3L, 6.0L & 6.2L V8 Mac Performance Instructions

2004 Chevy HD Truck Duramax Diesel High Output “LLY” Installation Instructions

Tools Required For Installation:
Flat Head Screwdriver
8mm, 10mm Socket
Ratchet & Extension
3/32”, 5/32” Allen Wrench
#T20 Security bit (Included)
1. Disconnect the negative battery cable. Disconnect the Mass Air Flow (MAF) sensor wiring harness. Using the supplied T-20 Security bit, remove the two screws and the Mass Air Flow sensor from the tube (save the sensor for reuse). Loosen the hose clamps on each end of the factory intake tube assembly.
2. Remove the factory filter minder and grommet.
3. Remove the factory intake tube assembly from the engine. Rock the factory air box back and forth and remove it from the vehicle. There are only grommets holding it in, no bolts.
4. Using a 10mm socket, remove the five bolts and mounting plate from the engine compartment.
5. Assemble the Airaid Cool Air Dam panels (#2, #3) using five 6-32x 5/16” screws (#9), #6 flat washers (#10) and 6/32 keps nuts (#11).
6. Using three ž-20x 1/2” button head bolts (#12) and 1/4” flat washers (#13), install the filter adapter (#4) on the Airaid Cool Air Dam.

Get pdf 2004 Chevy HD Truck Duramax Diesel High Output “LLY” Installation Instructions

01-06 Chev/GMC 6.6L Duramax Diesel Extended Cab Short & Long Bed Installation Instructions

Removal of stock system:
1. Apply a penetrating lubricant liberally to all exhaust fasteners, hangers and rubber insulators.
2. Using a 15mm socket or wrench, disconnect the factory exhaust system at the four bolt flange located behind the catalytic converter. If the vehicle is not equipped with a catalytic converter disconnect the four bolt flange located approximately under the passenger side seat.
3. Remove the exhaust system from the rubber insulators and remove from under the vehicle. If a hoist is not available for use, it may be necessary to cut the tail pipe behind the muffler for removal of the system.
4. Unbolt the OEM hanger from the transmission and remove.
5. Loosen the factory band clamp and remove the stock front pipe. Some vehicles are not equipped with a catalytic converter. Do not discard the band clamp as it is required for the installation.
6. Remove the spare tire. You may not be able to reinstall your spare tire after the installation of this exhaust system.

Installation of MBRP Inc. Performance Exhaust:
1. Install the Front Pipe onto the factory down pipe using the band clamp removed previously. Do not fully tighten to allow for adjustment. For regular cab models, 3” must be removed from the non flared end.
2. Install the hanger removed previously by sliding the outside hole in the rubber insulator over the hanger on the Front Pipe and re-connect to the transmission.
3. Install the 4″ to 5” Adapter over the Front Pipe. Then connect the Mid Pipe to the 4″ to 5” Adapter at the slip joint placing the bend around and under the cross member. Regular cab models do not have this cross member. The Mid Pipe does not require cutting to fit crew cab trucks. For extended cab trucks, approximately 9―” needs to be cut off the end with the longest straight section of pipe. For regular cab trucks remove 2” from the end with the shortest straight section of pipe and approximately 11―” from the end with the longest straight section of pipe. (Installation tip: Temporarily hang the Muffler and the Tail Pipe in place and measure to the Intermediate Pipe to verify the length required).
4. Rotate the Mid Pipe toward the drive shaft and loosely install the Hanger Clamp with the shortest hanger. This will support the Extension Pipe during the Muffler installation. Regular cab trucks do not require the installation of this Hanger Clamp.
5. Crew cab & extended cab long bed trucks require the use of the 18″ Extension Pipe provided. This is to be positioned between the Muffler and the Mid Pipe. The 18” Extension Pipe is not required with short box trucks.

Get pdf 01-06 Chev/GMC 6.6L Duramax Diesel Extended Cab Short & Long Bed Installation Instructions

99-07 Chevy & GMC Full Size Part # 000937, 000938 Installation Instructions

REMOVAL:
1. Engage the steering column / ignition switch lock with the steering wheel & wheels centered. (NOTE It may be necessary to remove the upper and lower steering shaft bolts prior to locking for accessibility)
2. Remove the two bolts holding the upper shaft in place. One is located in the engine compartment; the second is located under the dash at the base of the steering column.
3. Compress factory shaft assembly and remove it from under the dash. Do not spin wheel with shaft removed.

INSTALLATION:
4. Insert the tubular end of the Borgeson shaft from under dash through the firewall. Insert the male end of the universal joint into the steering column base and reinstall bolt.
5. Extend the Borgeson shaft to mate with lower shaft assembly in the engine compartment and reinstall bolt.
6. Torque each of the bolts to 60 ft/lb…NOTE…Failure to torque these bolts may cause a loose feeling in the steering.

Get pdf 99-07 Chevy & GMC Full Size Part # 000937, 000938 Installation Instructions

2001-2004 Chev/GMC Duramax Diesel “Cool Duals” Installation Instructions

Removal of stock system:
First using 15mm socket or wrench, remove four (4) nuts at flange located approximately under the passenger side seat. Remove rear exhaust from rubber hangers and remove the system from under the truck.
NOTE: If you have purchased the optional front pipe, Remove the stock front pipe on the truck by removing the exhaust hanger on the transmission using a 13mm socket, then remove the band clamp at the front of the pipe, then remove stock front pipe from the truck. ( Note: the band clamp will be re-used during the installation of your new MBRP system)

Standard installation:
Install the slip joint to the front pipe. ( Four Bolt Flange )
Install extension pipe into the slip joint (Installation tip: Temporarily hang the muffler and tail pipe in place using the two OEM rubber hangers and measure to the down pipe to determine the length needed) approximately 9―” needs to be cut off for extended cab short bed and 20″ for the regular cab long bed. Crew Cab Long Bed Trucks Require an 18″ extension.
Install muffler over the extension pipe(s)
Install the Over axle pipe over the muffler outlet, the muffler outlets will be in a vertical position. Install the second half of the driver side tail pipe to the over axle pipe using the frame hanger provided. ( Crew Cab Long Beds may require drilling )
Install the passenger side tailpipe over the bottom muffler outlet from the rear of the truck using the frame hanger provided. ( Crew Cab Long Beds may require drilling )
Install clamps around pipes where needed, be sure exhaust is in place before tightening
clamps. Starting at the front-pipe, tighten all connections.

Get pdf 2001-2004 Chev/GMC Duramax Diesel “Cool Duals” Installation Instructions

Specialty Tigertop Installation Instructions

Install Front and Rear Aluminum Angles
Using the bolts from the factory hard top or those supplied in the kit, install the aluminum angle rails in the existing holes on the top of the body edge. Fasten the bolts with the 5/16″ Nuts and 5/16″ Washers from the parts kit. There should be a 3″ space between the two pieces on each side for the Bow Mounting Bracket. There will be an extra hole at either end of the rails. Drill a 3/16″ hole in the body at these locations and use the #14 x 1/2″ Sheet Metal Screws to secure the rails in place.

Install Bow Mounting Brackets
Locate one of the Bow Mounting Brackets and place it in the space between the side railings. The outside edge of the Bracket should be flush with the railing. Mark the two outside holes.
Center punch your marks and drill 5/32″ holes at these locations. Tighten the bracket in place using 2 #10 Sheet Metal Screws.
IMPORTANT: The Bracket secures to the vehicle by using two Sheet Metal Screws. Use the two holes in each bracket which are closest to the outer edge of the body.

Install Front Bow.
Connect the two halves of the Front Bow Assembly with a Bow Coupler and slide a short Bow Cover over each leg of the Bow. THE TWO LARGE HOLES IN THE FRONT BOW ASSEMBLY SHOULD FACE THE FRONT OF THE VEHICLE.
Mount one leg of the Front Bow Assembly into the front of the Bow Mounting Bracket, using the Clevis Pin and Hairpin Keeper. Repeat this process for the other leg of the Front Bow Assembly.

Get pdf Specialty Tigertop Installation Instructions

TracVan Double Installation Manual

TracVan installation is straightforward, and should take you under 20 minutes to complete. You’ll attach the Crossbars to the Corner Brackets, then attach this assembly to the Gutter Rails of your van.
1. Verify that you have received the correct parts using the attached Assembly Drawing and Packing Checklist.
2. Fit the Rubber Strip on the lower edge of each Corner Bracket.
Do not install strip:
• On 2000+ Ford 150 Econoline vans.
• If using the Gutter Spans
3. Insert 2 (5/16” x 1 3/4 ” long) Socket Head Cap Screws through the Lock Washers and then into the holes in each Corner Bracket Tab.
4. Insert the J-Hooks with Neoprene Strips through the Assembly Slots at the base of the Corner Bracket. Then insert 2 Brass Nuts into the opening of the J-Hook clips. Thread each screw approx. 1/4 in. into the J-hook’s brass nut. (Do not completely tighten screws) Repeat for each Corner Bracket, (2 hooks for each Bracket). (See Fig. 1)
5. Now you’re ready to attach the Crossbars (see Shim Installation, page 6, if shims are required on front and rear racks). Insert the heads of four 1 1/2” T-Bolts into the Crossbar Slot on the bottom of each Crossbar (the bottom is the side with the Flat Recess) (see Fig. 2). Slide 2 T-Bolts to the left side and 2 T-Bolts to the right.
6. Attach a Corner Bracket assembly to the Crossbar by inserting the T-Bolts through the two holes in the Corner Bracket. Partially tighten and secure with the Self Locking Nuts – enough to hold the Corner Bracket in place. Repeat for each of the remaining three Brackets.
7. Slide the Crossbar Tiedowns onto the Crossbar by insert- ing the T-Bolts into the top Crossbar Slot.

Special Installation notes:
• All 1998+ Chevy Express / GMC Savanna (G-Series Vans) require the supplied Gutter Span, which are designed to span the putty filled rain gutter of the Van for maximum strength. If you use the supplied Gutter Spans, refer to “Roof Installation B” instructions on page 5 for proper installation.
• All 2000+ Ford Econoline Vans: DO NOT install the rubber strips to the Corner Brackets.
• When installing a TracVan Triple (SKU# 29056) to a Chevy Express / GMC Savanna (G-Series Vans) and Ford Vans with curved roofs you’ll need to add the supplied Shims, to compensate for the gutter’s curve.

Get pdf TracVan Double Installation Manual

Maxxcams Advanced Leveling Systems Installation

Maxxcams are designed to add additional height adjustment to your vehicle. Under no circumstances should the truck be adjusted beyond the factory height measurement. The shock absorber is the suspension height limiter and only stock length shock absorbers are recommended without modification whatsoever. Adjusting vehicle suspension height beyond the maximum factory height can cause binding of crucial steering and suspension components.

These instructions and warnings shall not be substituted for the factory service Manual. Torsion bars are preloaded in the vehicle. Only Experienced suspension technicians with a working knowledge of the system and the properly designed tools and SAFETY EQUIPMENT should attempt installation of this part.

Installation of this product and all the adjustments should be performed by a licensed certified technician. Using the correct tools and procedures. Adjusting the suspension beyond the factory recommended maximum height can cause binding and accelerated wear of critical steering and suspension parts. Under no circumstances shall Suspension Maxx held liable for any damage or loss of use due to incorrect installation of adjustment. Purchaser of this product assumes all liability.

Get pdf Maxxcams Advanced Leveling Systems Installation

99-up Chevy/GMC Truck Tailgate Cap Instructions

1. Remove the factory plastic tailgate cap.
A. Remove any tape residue from the truck by wrapping a cloth shop towel or terry cloth rag tightly around knuckles and push firmly against remaining tape.
B. Remove any remaining glue or dirt with Naptha, Paint Thinner or Adhesive Remover. Then clean surface with Isopropyl alcohol and wipe clean.
C. If you have purchased the gray smooth paintable Tailgate Cap go to step 2; if you have purchased the black textured Tailgate Cap go to step 3.
2. Paint Smooth Tailgate Cap according to painting instructions on back of this page. Do not paint black textured Tailgate Cap - this one is meant to be left black.
3. To Install: Peel upper tape protective strip (see #1 below). Then peel back 1”-2” of lower tape protective strip (see #2 below) and fold downward to create a pull tab. Center the cap and push down onto the tailgate, holding the exposed tape on lower corner away from the tailgate until cap is in place. Now slowly pull down on tab and pull protective strip from under the lower edge of tailgate cap. Once the strip is removed, push firmly against cap to set the tape.
Warranty is void if factory tailgate is not cleaned according to instructions and if installation instructions are not followed.

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AT11003 Installation Instructions

Apply for below vehicle:
2000-2007 Chevy Silverado 1500 Crew Cab
2000-2007 GMC Sierra 1500 Crew Cab
2001-2007 Chevy Silverado HD Crew Cab
2001-2007 GMC Sierra HD Crew Cab

2006 and newer General Motors trucks have a larger cab mount bolt than in previous years. You will need to reuse your factory cab mount bolts when installing this kit on those trucks.

1. Before installing, review the installation instructions carefully. Be sure you have all hardware shown in the diagram. (You may have some extra hardware)
2. Locate the three body mounts located under the cab behind the inner wall of the rocker panel.
3. Locate the front and rear mounting brackets. The rear brackets are longer than the front brackets.
4. Remove the front body mount bolt and discard. Be sure to keep the rubber bushing. Using a long bolt, lock washer and flat washer install the rubber bushing and then the front bracket. Leave the bolt loose for now. Repeat this step for the middle and rear brackets.
5. Identify the driver and passenger side step tubes. Install a M14 bolt with lock washer and flat washer through the bracket into the rear end of tube. Leave it loose for now.
6. Install a M14 bolt with lock washer and flat washer through the bracket into the front end of tube.
7. Install M10 bolt, lock washer and flat washer through center bracket and into the hole in the tube that is in line with the bracket. Tighten this bolt being careful not to strip the threads in the tube.
8. Next, tighten the M14 bolts holding the tube ends to the brackets. Then tighten all remaining bolts.
9. Repeat the steps above on the other side.

Get pdf AT11003 Installation Instructions

2007-08 Chevy/GMC Ton, Crew Cab, 2/4wd 3″ Body Lift Installation Instructions

Zone Offroad Products recommends this system be installed by a professional technician. In addition to these instructions, profes-
sional knowledge of disassembly/ reassembly procedures and post installation checks must be known. Minimum tool requirements
include the following: Assorted metric and standard wrenches, hammer, hydraulic floor jack and a set of jack stands. See the “Special
Tools Required” section for additional tools needed to complete this installation properly and safely.

Pre-inStallation notes
1. Special literature required: OE Service Manual for model/year of vehicle. Refer to manual for proper disassembly/reassembly procedures of OE and related components.
2. Adhere to recommendations when replacement fasteners, retainers and keepers are called out in the OE manual.
3. Larger rim and tire combinations may increase leverage on suspension, steering, and related components. When selecting combinations larger than OE, consider the additional stress you could be inducing on the OE and related components.
4. Post suspension system vehicles may experience drive line vibrations. Angles may require tuning, slider on shaft may require replacement, shafts may need to be lengthened or trued, and U-joints may need to be replaced.
5. Secure and properly block vehicle prior to installation of Zone Offroad Products. Always wear safety glasses when using power tools.
6. If installation is to be performed without a hoist, Zone Offroad Products recommends rear alterations first.
7. Due to payload options and initial ride height variances, the amount of lift is a base figure. Final ride height dimensions may vary in accordance to original vehicle attitude. Always measure the attitude prior to beginning installation.

INSTALLATION INSTRUCTIONS
1. Park the vehicle on a clean, flat surface and block the rear wheels for safety.
2. Remove the negative battery cable first, then the positive battery cable. If equipped, the Supplemental Restraint System (airbags) will be deactivated when the battery is disconnected.
3. Measure and record the space between the bumpers and the body as well as the cab to the bed for reference during the installation.

Get pdf 2007-08 Chevy/GMC Ton, Crew Cab, 2/4wd 3″ Body Lift Installation Instructions

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