Automotive Manual PDF

STEP 1. Remove the contents from the box and check for any damage. Verify all parts against the parts list.
STEP 2. Read and understand instructions completely before beginning installation.
STEP 3. Determine passenger and driver brackets. SEE FIGURE 1.
STEP 4. Remove (16) push type retainers from lower splash shield. Remove plastic splash shield to gain access to mounting locations.
STEP 5. Locate bolts that hold the frame brace and bumper brackets to vehicle. Remove bolts using a 17mm and 14mm socket and ratchet.
STEP 6. Install bracket between lower radiator support and frame brace using (2) 1/2” flat washers on top of bracket’s frame brace slots and replace bolts. Install (1) 3/8-16 x 1.00” hex head bolt, (1) 3/8” lock washer and (2) 3/8” flat washers. Leave loose. SEE FIGURE 1. NOTE: It may necessary to loosen body mount bolt holding the frame brace to gain enough clearance to slide brackets in place.

CUTTING INSTRUCTIONS
The template works best is placed on top side of splash shield (the side towards the vehicle). Locate two oval slots that measure 3 3/8” x 13/16”. Cut out template and place over appropriate slots. Hold in place using masking tape. Drill 1/4” holes at each of the small circles. Cut splash shield from each drilled hole to drilled hole. It may be necessary to use a straight edge to ensure a straight cut.

STEP 7. Locate top mount brace bolts. These are accessed from front of vehicle through center opening of bumper. With a 12mm wrench, remove bolt towards inside of frame rail. NOTE: This bolt will be replaced with the longer one supplied in bolt kit. SEE FIGURE 2.
STEP 8. Determine passenger and driver support braces and install through bumper opening. Attach braces to frame rail where bolt was previously removed in Step 7 as shown. Leave loose. SEE FIGURE 2.
STEP 9. Determine passenger and driver uprights, hood bar/top tube assembly, center tube and bottom tube. NOTE: Uprights are positioned so raised side of bolt holes are facing each other. SEE FIGURE 3.
STEP 10. Attach uprights to hood bar/top tube assembly, center tube and bottom tube using (4) 1/2-13 x 1.50” stainless steel flat head bolts, (2) 2.75” plastic washers, (2) 3/8-16 x 1.00” stainless steel button head cap screws, (2) 3/8” stainless steel internal tooth lock washers and (2) 1.625” plastic washers. Level tubes and torque 1/2” fasteners to 60 FT.LBS. and 3/8” fasteners to 30 FT.LBS.
STEP 11. Determine passenger and driver wing assemblies. Install driver side wing assembly using (4) 3/8-16 x 1.00” stainless steel button head cap screws, (8) 3/8” stainless steel flat washers, (4) 3/8-16 stainless steel nylock nuts and 1.00” plastic washers. Tighten and torque to 35 FT.LBS. Repeat for opposite side.
STEP 12. Lay Sportsman face down in front of vehicle and attach to bottom bracket using (1) 1/2” hex head bolt and (2) washers per side. Leave loose. Rotate Sportsman to vehicle and install remaining hardware in bottom brackets. Fasten top brace to uprights using 3/8” stainless steel fasteners as shown. SEE FIGURE 1.
STEP 13. Level and center as desired. Tighten and torque bottom brackets as follows: 12mm fasteners to 61 FT.LBS

Get pdf 2003-UP Honda Pilot Sportsman Assembly Installation Instructions