Automotive Manual PDF

Installation Instructions. Read Me!
I. DISCONNECT NEGATIVE (-) BATTERY CABLE
II. Remove Factory Intake Assembly
a) Loosen the factory hose clamps on each end of the factory intake tube assembly.
b) Using a flat head screwdriver, gently pry the radiator hose bracket from the factory intake tube assembly and remove from vehicle.
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Remove the Stock / OEM Instrument Panel
1) Make sure to disconnect the vehicle battery before you begin to remove the instrument panel.
2) Remove the two 5/16” screws which are holding the steering column tight to the base of the dash. This allows the steering column to drop down slightly.
3) Remove the six screws that are holding the panel to the dash.
4) Remove the light switch knob. To do this, push in the button at the top of the switch box housing (under the dash) and then pull out the light switch knob and shaft. Next, unthread the nut holding the light switch box to the instrument panel and remove the light switch box.
5) Remove the wiper knob. To do this, loosen the small set screw, pull the knob off and then unscrew the bezel.
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FRONT DISASSEMBLY:
1. With vehicle on flat level ground set the emergency brake and block the rear tires. Place floor jack under the lower control arm’s front cross member and raise vehicle. Place jack stands under frame rails, behind the front wheel wells then and lower the frame onto the stands.
2. Remove both front factory skid plates located in front of and under the front differential using 15mm socket.
WARNING: Be extremely careful when loading or unloading the torsion bars; there is a tremendous amount of stored energy (load pressure) in the bars. Keep your hands and body clear of the adjuster arm assembly and puller tool in case anything slips or breaks.
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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.
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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.
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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.
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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.
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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
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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: [__________]
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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.
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