Chevrolet 170 Automobile User Manual

CHEVY IMPALA
1992 - 1996
LSD INSTALLATION
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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INSTALLATION INTRODUCTION
1.
REMOVING THE FENDER, DOORS FROM THE A-PILLAR AND DISCONNECTING THE
WIRE HARNESS @ THE DOOR JAM
2.
REMOVING THE EXISTING DOOR HINGES FROM THE DOORS; TOP AND BOTTOM.
3.
MODIFYING THE INTERNAL FENDER AREAS FOR THE HINGE CLEARANCE.
4.
MODIFYING THE ELECTRICAL HARNESS.
5.
INSTALLING THE GROUND PLATE TO THE A-PILLAR AND THE SWING ARM TO THE
DOOR.
6.
HANGING AND ALIGNING THE VEHICLE DOORS.
7.
INSTALLING THE FENDER AND CHECKING FOR CLEARANCE.
8.
REMOVE FENDER AND ROUTE THE WIRING.
9.
RE-INSTALL FENDER AND CHECK FOR CLEARANCE.
10.
JOB COMPLETE!
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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Installation Instructions LamboStyleDoors
(The instructions are to be used as a reference only. Please repeat steps for both doors.)
Pre-installation check list:
•Battery disconnected •Front bumper removal •Front fender removal
•Vehicle must be accident free •Vehicle must have inner fender cover
Preparations:
(Disassemble parts according to the vehicle manufacturers’ specifications)
•
•
Disassemble the door stopper
Disconnect the wire harness between the chassis and the door (remove the harness from the door interior
when necessary)
•
Disassemble the door. For this procedure, remove the pin between the hinges.
•
Modify the hinges at the A-pillar and on the door (please see enclosure “modifying the hinges”.
•
Extend the factory door wire harness with the enclosed wire harness extension kit.
(See enclosed “wire harness extension”.
•
Modify the fender
(See enclosed “modifying the fender”.
•
Relocate the door lock vacuum case (when necessary).
(e.g. from the passenger’s side inner fender to the engine compartment)
•
Modify the windshield washer reservoir (when necessary).
(see enclosed “modifying the windshield washer reservoir”)
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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DANGER WARNINGS
LSD Doors must be installed according to the provided vehicle specific instructions from LSD Doors and installation should be performed by an authorized dealer.
Always follow the latest accident prevention regulations (not applicable for North America) for each step to
prevent any serious bodily harm or injury.
Extending the factory wire harness must be completed according to the vehicle manufacturer‘s guidelines for
cable repairs. When working with Share-data bus systems please take special care to correctly rerouting the
wires and not to damage the wire insulation/shielding, twisting of the cables or interruption of any other systems (check with the specifications of the vehicle manufacturer).
When modifying vehicles equipped with door side air bag systems, the functionality of the air bag system
must be re-inspected through the vehicles authorized dealer.
During final door adjustments please make sure that the door closes and locks correctly as o.e.m. specifications (see original door close angles, lock and gapping positions etc.)
Please pay special attention while working in the operation area of the hinge system (especially when working
directly with the pivot mechanism or in the overall door operation zone).
All vehicle doors must be securely closed before setting vehicle into motion. Operating a vehicle with the
doors open is strictly prohibited.
Supplied vertical lifting door warning decals must be placed on the vehicles front side windows, clearly visible
from both inside and outside. Not placing decals on your vehicle might void your vehicle operating license
(not applicable for North America).
DO NOT install heavier speaker systems without first raising the pressure of the gas spring.
Please adjust the horizontal opening angle of the doors for maximum entrance space.
Please pay attention to your gas springs and make sure they open and maintain your door at the maximum
opening angle under all operation vehicle conditions.
Make sure you empty the door pockets/storage compartments, so objects will not fall out once the door is
raised and also not to offset the correct balance of the gas spring.
WARNING: The gas spring is under extreme pressure! Please make sure the snap rings are installed correctly and are snapped their respective guides.
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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!
Attention notice:
An additional inside support handle must be installed to solve the issue of possible difficulty of griping the
door, when raising and lowering your door from your seated position.
If there are white lights on your door, these must be made ineffective, e. g. taking of the bulb and bulb holder
according to fig. 5.22 ECE-law no. 48.
After mounting the LSD hinge system you must reinstall your OEM inner fender covers to keep your LSD
hinges free from debris and corrosion.
You must have an authorized workshop check that the central locking system (if equipped) is working properly.
You must have an authorized workshop check the functionality of all systems, switches and components
(including: loudspeakers, alarm system, CAN data bus systems, window lifts, crash-sensor, memory seat adjustment, mirror adjustment and heating, etc. if equipped).
While adjusting the door please take special care to position it in the matching door frame as not to cause any
damages to paint etc.
In case any chassis modifications were performed, please use the supplied chassis glue (if required for specific application) to seal any openings on the A-pillar or doors (make sure panels are free from grease and
dust before applying chassis glue for a superior water tight seal).
NOTE: please be aware your car might have different factory installed equipment from our tested R&D vehicle, in this case please contact your LSD dealer to order higher or lower power gas damper units (an additional cost may apply).
Please note that the power of the gas dampers may fluctuate due to ambient temperature variations, the
opening and closing forces may also differ according to damper manufacturers specifications (warranty
claims will only be honored if there’s an internal defect or an error in production).
All LSD hinges come with a protective oil coating, please remove coating and then apply the included PSK
spray for superior sealing of the finish.
If any body work is performed, use Corrosion prevention methods according to the vehicle manufactures
specifications.
Updated installation instructions can be found on www.lsd-doors.com (guide notes subject to change without
notice).
General installation instructions:
A second person makes the work much easier. Please instruct the second person before start working.
It is recommended to keep your LSD door hinges maintained on a regular basis for a lifetime of trouble
free operation.
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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General Lubrication Information
In order for the LSD Door System to function properly, adequate lubrication is essential at all pivot
points on the system. Periodic lubricating of all pivot points is highly recommended on a consistent
basis. This helps in the life of all bearings involved.
Listed below are helpful hints of when to lubricate:
- After washing the vehicle, open the doors and check to see that all pivot points are properly greased
- Every three months, open doors and check to see that all pivot points are properly greased
- If the vehicle is subject to a harsh environment, such as salt or sand, it is critical that all pivot points stay
lubricated, especially if the doors are being used frequently, open doors and check to see that all pivot
points are greased properly
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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HARDWARE LIST ( per vehicle side)
1x A
5X B
1x C
3x D
Snap ring
Cable ties
Gas Damper 2450
M.A.R.A Shim
1x G
2x H
LSD Hinge Assembly
Cover plate
1x E
1x
F
LSD Swing Arm
LSD Ground Plate
2x I
1x J
LSD Warning notice
Shim Roller Mount
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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OEM
C
F
OEM
C
A
E
A
OEM
C
OEM
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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ORIGINAL EQUIPMENT CHASSIS HINGE REMOVAL MODIFICATION
IMPORTANT NOTE: The following instructions given, in sequential order, is a step-by-step procedure to
minimize any installation difficulty that may occur. By skipping steps, un-necessary problems can arise during
the installation process.
On this particular vehicle, the hinges are bolted to the A-Pillar. Using a wrench, un-bolt both the two top
mount bolts and the two bottom bolts that attach the hinge/door to the A-Pillar. Remove the door/hinges from
the A-Pillar and carefully put aside.
A-PILLAR
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 1
INNER FENDER MODIFICATION
For this particular application, once the outer fender has been removed, the inner fender needs
to be modified, to accommodate the new LSD hinges. The following pictures show the areas
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 1
INNER FENDER MODIFICATION –cont’dFor this particular application, once the outer fender has been removed, the inner fender needs
to be modified, to accommodate the new LSD hinges. The following pictures show the areas
(outlined in white) that will need to be removed.
1a.
Using a cutting tool, a manual or pneumatic saw, begin cutting along the white line to
wards the top of the inner fender (Photo 1). Cut-out completely and remove (Photo 2).
1b.
After the first cut has been done, this is what it should look like (Photo 3).
65mm
80mm
PHOTO 1
PHOTO 2
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
PHOTO 3
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STEP 1
INNER FENDER MODIFICATION –cont’dFor this particular application, once the outer fender has been removed, the inner fender needs
to be modified, to accommodate the new LSD hinges. The following pictures show the areas
(outlined in white) that will need to be removed.
1c.
The secondary cut for the removal of the large inner fender lip is done the same way as
the first. With this area already outlined, begin cutting the lines you have marked
(Photo 3).
1d.
The final look of the area (Photo 4) is shown. We recommend that painting the exposed cut areas to match the color of the inner fender. This is done to prevent any
rusting of the exposed areas.
PHOTO 3
PHOTO 4
1e.
This portion of the inner fender modification is complete.
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 2
INNER FENDER MODIFICATION –cont’dFor this particular application also, the outer fender also needs to be modified, to accommodate the new LSD hinges. The following pictures show the areas (outlined in white) that will
need to be removed.
2a.
This cut for the removal of the fender lip is done using a cutting tool. Outline the area
using the dimensions given to you. This (Photo 5) shows the before cut.
2b.
The final look of the area (Photo 6) is shown.
PHOTO 5
2cm
5mm-7mm
3.5cm
7.5mm
22cm
23.5cm
PHOTO 6
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 3
DIS-ASSEMBLING THE SWING ARM FROM THE GROUND PLATE
3a.
Your new LSD Door Hinges have come assembled.
3b.
As identified in (Photo 8), disassemble the swing arm from the ground plate. Un-bolt
all four mounting bolts or allen-heads and remove completely.
E
F
PHOTO 8
PHOTO FOR REFERENCE ONLY
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 4
MOUNTING THE GROUND PLATE TO THE A-PILLAR
4a.
Using the kit supplied mounting hardware for the Ground Plate, attach it to the A-Pillar.
Finger tight initially, then using a wrench, torque to specifications. The photos below
show the top and bottom mounting points of the Ground Plate.
BOTTOM MOUNT
4b.
TOP MOUNT
For this particular application, there is an additional mount point that stiffens the top of
the Ground Plate, giving the Ground Plate more rigidity. The photo below shows, using existing hardware, anchoring the top of the Ground plate to the top of the A-Pillar.
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 5
MODIFYING THE CHASSIS WIRING HARNESS
IMPORTANT NOTE: Prior to beginning extending the wiring harness from the A-pillar,
each individual wire needs to be cut one at a time. Each wire that is cut, has to be staggered
(See 5g) from the previous cut wire. By doing this, you will eliminate, when wrapping all the
wires, one large taped ball.
5a.
If the wiring harness comes equipped with an insulation cover, this will need to be
removed.
STEPS 5b thru 5f are for REFERENCE ONLY (using white wire as reference)
5b.
Isolate a single wire (Photo 9). Start the first cut on the white wire approximately 3”
from the door frame.
5c.
Cut the wire sheath (insulation) (coming from door frame) back approximately
1/4” (Photo 10). Twist the end tight.
5d.
Cut the wire sheath (insulation) (from kit supplied white wire) back approximately 1/4”.
Twist the end tight.
5e.
Using the kit supplied heat shrink connector ends, insert the wire ends into the connector, one from each end (Photo 11).
5f.
Using the heat gun, shrink wrap the connector ends to securely mate with the wire
ends (Photo 12).
PHOTO 9
PHOTO 10
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
PHOTO 11
PHOTO 12
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STEP 5
MODIFYING THE CHASSIS WIRING HARNESS –cont’d5g.
VERY IMPORTANT:
5h.
Remember to stagger the cuts for each individual wire. This will eliminate having a
large wrap and will allow for minimal size and maximum flexibility.
5i.
In the photo below an (INCORRECT) version is shown. By cutting it this way, wrapping
the wire at the end, will create a large ball in the middle of the newly extended wire harness. Wire harness flexibility would be minimal.
5j.
By staggering the cuts, (CORRECT), you eliminate creating a large taped ball, thus
making it easier to install back in the chassis. Wire harness would have minimal size
and maximum flexibility.
5k.
On this particular install, a kit supplied cover plate is used on the door itself (Photo 13).
This cover plate is not mounted with any hardware, but instead is held in place by the
LSD Swing Arm.
5m.
Once both cover plates have been fed onto the new extension wire harness, you are
able to attach the wire connector end of the A-Pillar (Photo 14).
INCORRECT CUTS
PHOTO 13
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
CORRECT CUTS
PHOTO 14
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STEP 5
ROUTING THE WIRE HARNESS
IMPORTANT NOTE:
5n.
Prior to mounting the Swing Arm to the door, the wire harness needs to be fed through
the Swing Arm, as shown in (Photos 26a)
PHOTO 26a
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 6
MOUNTING THE LSD SWING ARM
6a.
Using the existing O.E.M. nuts, mount the LSD swing arm on the door, matching
up each respective mount hole. Two mount holes at the top and two at the bottom
(Photo 15). Locate the mounting nuts at the center of their respective mount holes.
6b.
Using a wrench, torque the bolts to 20ft-lb.
OEM
OEM
PHOTO 15
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 7
MOUNTING THE DOOR TO THE A-FRAME IMPORTANT NOTE: THIS STEP SHOULD BE
DONE WITHOUT THE GAS SPRING INSTALLED
7a.
Place the door back on the vehicle and close the door completely.
7a.
Install the MAGICSTIK into position (Photo 16) Initially, this is done for mounting purposes only, using the MAGICSTIK as a guide.
7b.
Lifting the door into position, guide the MAGICSTIK into its mating block (Photo 17),
manually holding the door there, as close to the closed position as possible.
7c.
Attach the swing arm to the ground plate with the four (4) kit supplied bolts and adjust
the door via moving the swing arm adjustable plate connection mount with the horizontal door gap adjuster in the right or left direction until the gap measurement is like the
original (Photo 18).
PHOTO 16
PHOTO 18
IMPORTANT NOTE:
Torque mounting bolt to 10ftlb.
PHOTO 17
INITIAL ADJUSTMENT OF THE DOOR
7d.
Adjustment height of the door is by moving the Ground plate (F) vertically. Make
sure the mounting hardware is loosened to be able to do this.
7e.
Adjustment depth of the door is by moving the door horizontal. Make sure the mounting hardware is loosened to be able to do this.
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 8
MOUNTING THE GAS DAMPER (after correct gap distance has been established)
IMPORTANT NOTE:
•
PRIOR TO MOUNTING THE GAS DAMPER AT ITS RESPECTIVE MOUNTING POINTS, WE HIGHLY
RECOMMEND USING AN ANTI-RUST LUBRICANT, WIPING DOWN THE MOUNT POINTS TO PREVENT RUSTING.
•
KEEPING THE MOUNTING POINTS LUBRICATED, ENHANCES THE LONGEVITY OF THE LSD
DOOR SYSTEM TO WORKING PROPERLY
GAS DAMPER
TOP PIVOT POINT ON LSD
SWING ARM
GAS DAMPER
BOTTOM PIVOT
POINT ON LSD
GROUND PLATE
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 8
MOUNTING THE GAS DAMPER (after correct gap distance has been established)
8a.
Hang (mount) the gas damper on the mount point of the swing arm (Photo 22). Secure
it with the kit supplied security ring, by using needle-nose pliers.
8b.
NOTE: Use care when installing the security ring.
8c.
The rubber o-ring, located on top of the gas damper has to be moved (Photo 23) between the Ground plate and the top of the ball joint of the gas damper (Photo 24).
PHOTO 22
8d.
PHOTO 23
Carefully pivot the door up and hang in the gas damper at the fitting point of the Ground
plate. Secure it with the kit supplied security ring (Photo 25)
PHOTO 24
PHOTO 25
DANGER: The gas damper is under extreme pressure! Please make sure the security
rings are installed correctly and are snapped in their respective guides.
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 9
FINAL DOOR ADJUSTMENT… IF REQUIRED
9a.
With the gas spring installed
9b.
At this point of the installation, open and close the door slowly. Check and see if the
Magic Stick aligns correctly to the Magic Stick receptacle. If adjustment is necessary,
adjust the Magic Stick receptacle to align with the Magic Stick (Photo 20). In some instances the Magic Stick receptacle has maxed out on adjustment. If this scenario
arises, spacers must be used to align both the Magic Stick and Magic Stick receptacle.
PHOTO 20
9c.
If the Magic Stick (Photo 20) (lower adjustment screw) is not in the correct position
when the door is closed, a spacer (Photo 21) has to be installed under the M.A.R.A
as shown in the pictures.
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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IF REQUIRED
9d.
With the gas spring uninstalled.
9e.
If spacer (s) installation is needed, install one at a time, starting at the top, (Photo 21)
working your way to the bottom, to see if that particular spacer aligns the door correctly.
Begin at the top mounts, STEP 1A to STEP 1B, etc, etc.
2
L
L
2
STEP 1A - TOP
STEP 2A - BOTTOM
L
L
2
2
STEP 1B - TOP
STEP 2B - BOTTOM
PHOTO 21
Re install gas spring and check door alignment again. Repeat if necessary.
50061011 Chevy Impala SS
A Division of KW automotive North America, Inc
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STEP 10
ROUTING THE WIRE HARNESS
10a.
Pivot the door carefully up and make sure there is sufficient clearance on the fender, Apillar and hood. If necessary, adjust the Ground plate or the LSD swing arm
again.
10b.
Lay the wire harness on and attach it to the marked points shown (Photo 26). Secure
the wire harness with the kit supplied cable ties.
Allow for movement
in this area, check
with fender and door
ZIP TIE/TIE WRAPS
Exact locations for
clips may vary for the
amount of wiring on
vehicle
PHOTO 26
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A Division of KW automotive North America, Inc
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11.
ROLLER ADJUSTMENT
NOTE: The door needs to be in the closed position for this adjustment to be properly
done.
11a.
Please adjust the slide roller so the LSD swing arm has the initial contact and preload while opening and closing of the door. (Photo 27).
11b.
To get the adjustment of the slide roller, we have designed an horizontal and vertical
adjustment to the slide roller mount.
IMPORTANT NOTE:
11c.
There may be at times when you have exhausted the travel on the adjustment and
still have not located the slide roller where its should be located.
11d.
To rectify this problem, included in the hardware kit, are spacer shims, that, if needed
would be located (Photo 28) between the slide roller mount and the main mount. This
would move the slide roller down slightly.
MAIN MOUNT
SLIDE ROLLER
PHOTO 27
TOP MAIN MOUNT
SHIM
PHOTO 28
SLIDE ROLLER MOUNT
PHOTO 28a
50061011 Chevy Impala SS
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COMMON TROUBLESHOOTING QUESTIONS and ANSWERS
Q1:
WHY DOES THE BOTTOM OF THE DOOR NOT SIT FLUSH, AT THE FRONT OR REAR?:
A1:
LSD door hinges are engineered and designed to compensate for this issue. They are designed to be
installed in the center location of all mounting slots. Some vehicles are different however; adjusting
the location of the swing arm mounts on the door will fix this problem. Mounting the swing arm towards the interior of the door, top or bottom will move the door out; mounting the swing arm towards
the exterior of the door will move the door in. In some cases, the mounting will be slightly different between top and bottom mounts.
Q2:
WHY DO THE DOORS “SPRING” A-JAR WHEN OPENING THE DOOR?:
A2:
LSD door hinges are engineered and designed to compensate for this issue. It is common on vehicles
that the left and the right sides are not quite the same. When a door “springs” open there is a misalignment between the swing arm and the ground plate. This can be remedied by increasing the distance
of the “third” point on the ground plate. The “third” point is usually located towards the front of the vehicle. Increasing the distance and angle of the ground plate to the vehicle will release any pressure
and/or contact between the swing arm and the ground plate.
Q3:
WHY DOES THE DOOR HITS/RUBS AGAINST THE FENDER WHEN OPENING?:
A3:
LSD door hinges are engineered and designed to compensate for this issue. Attaching the LSD hinge
in the center location of the slots and adjusting the magic stick such that the tuff lock is centered is the
optimum desired installation. Making minor adjustments to the “MARA”/“C” profile, the “third” point,
and/or the “Magic stick” should alleviate this problem.
Q4:
WHY IS THE WIRING HARNESS TOO LARGE FOR THE ROUTE SHOWN IN THE INSTRUCTIONS?:
A4:
LSD door hinges are engineered and designed to compensate for this issue. LSD wiring kits are designed for the MAXIMUM wires installed on vehicles. If additional wires are added or modified that
are larger than original, wiring routing might have to be modified. Vehicle owners are responsible
for this modified routing.
Q5:
WHY DOESN’T THE GAS SPRING HOLD THE DOOR UP?:
A5:
LSD door hinges are engineered and designed to compensate for original door weight, i.e. speakers
and electronics. NOTE: As temperature fluctuates, the gas pressure in each shock increases or decreases. Example; in the heat, the gas pressure will expand, in the cold; it has a tendency to contract.
Any modifications to the speakers or electronics may require a larger gas spring. Vehicle owners are
required to purchase these larger gas springs from their local dealer. If you have not modified your
door, your gas spring may be faulty. Vehicle owners are required to contact their local dealer for replacement(s).
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A Division of KW automotive North America, Inc
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A Division of KW automotive North America, Inc
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A Division of KW automotive North America, Inc
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A Division of KW automotive North America, Inc
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A Division of KW automotive North America, Inc
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A Division of KW automotive North America, Inc
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