CHEVY COLORADO
GMC CANYON
BODY LIFT
INSTALLATION INSTRUCTIONS
2004 - 2005 3” KIT # 10153
WARNING
Installation of a Performance Automotive Group body lift kit will change the vehicle’s center of gravity and handling characteristics both on- and off-road. You must drive the vehicle safely! Extreme care must be taken to prevent vehicle rollover or loss of control, which could result in serious injury or death. Avoid sudden sharp turns or abrupt maneuvers and always make sure all vehicle occupants have their seat belts fastened.
WARNING
Before you install this kit, read and understand all instructions, warnings, cautions, and notes in this instruction sheet and in the vehicle owner’s manual.
CAUTION
Proper installation of this kit requires knowledge of the factory recommended procedures for removal and installation of original equipment components. We recommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation. Installation of this kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of the vehicle. We strongly recommend that a certified mechanic familiar with the installation of similar components install this kit.
WARNING
This kit should only be installed on a vehicle that is in good working condition. Before you install the kit, thoroughly inspect the vehicle for corrosion or deformation of the sheet metal around the factory body mounts. If the vehicle is suspected to have been in a collision or misused, do not install this kit. Off-road use of your vehicle with this kit installed may increase the stress applied to the factory body mounts. We do not recommend that any vehicle with a body lift kit installed be involved in any extreme off-road maneuvers such as jumping. Failure to observe this warning may result in serious personal injury and/or severe damage to your vehicle.
WARNING
Many states and municipalities have laws restricting bumper heights and vehicle lifts. Consult state and local laws to determine if the changes you intend to make to the vehicle comply with the law. Before combining a body lift with a suspension lift, consult an installation professional to see how this will affect the vehicle.
WARNING
The installation of larger tires may reduce the effectiveness of the Braking System.
WARNING
Always wear eye protection when operating power tools.
WARNING
Before you install this kit, block the vehicle tires to prevent the vehicle from rolling.
WARNING
Accidental deployment of the air bag can result in serious personal injury or death. To avoid accidental deployment during installation of the kit, the Supplemental Restraint System (SRS, or airbag) must remain deactivated. Do not allow anyone near the airbag during installation. Refer to the factory service manual or owner's manual for the recommended procedure to disable the SRS. After you install the kit, reactivate the
SRS before driving the vehicle.
NOTE
Performance Automotive Group recommends using the Loctite® supplied in the kit on the threads of all kit nuts and bolts unless specified otherwise in these instructions.
1 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
Before Starting Installation
2. Measure and record distance between rear bumper and bed
NOTE
Kit parts are prefaced by the word kit and appear in
bold
print.
1. Carefully read all warnings and instructions completely before beginning.
2. Verify all parts have been received in this kit by checking the parts list at the end of this document.
Driver Side _____Passenger Side _____
3. Measure and record distance between cab and bed.
Driver Side _____Passenger Side _____
Engine Compartment
1. Battery Cables.
a. Disconnect both battery cables. Disconnect negative cable first, then positive cable.
NOTE
If parts are missing from kit, please be prepared to provide the following information:
1.
Name
of purchase location
2.
Bar Code
on side of box
3.
Date
above bar code
4.
Date
inside box cover
5.
Inspector #
from inside box cover
3.
Only install this kit on the vehicle for which it is specified.
If anytime during the installation you encounter something different from what is outlined in the instructions, call technical support at (928)
636-7080.
Positive
Cable
Negative
Cable
2. Airbag Fuse
.
4. Special tools needed: a. Welder or access to a professional welding shop.
NOTE
The location of the airbag fuse may vary; check the owner's manual. a. Remove fuse box cover.
b. Die grinder or similar tool capable of cutting metal.
b. Remove airbag fuse from fuse box.
c.
Fan clutch spanner wrench.
5. Park the vehicle on a clean, dry, flat, level surface and block the tires so the vehicle cannot roll in either direction.
Fuse Cover
Measurements
1. Measure and record distance between front bumper and fenders.
Driver Side _____Passenger Side _____
Fuse Box
2 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
Prepare to Install Kit
Front of Vehicle
1. Grille a. Remove two wire harness clips from upper headlamps.
c.
Remove seven clips and grille from vehcle.
Grille Clips
Grille
Wire Harness
2. Running Lights a. Remove two wire harness connectors from running lights.
Upper Head
Lamps b. Release four push down clips from upper grille area.
Wire Harness
Running Light
Bumper
3. Front Bumper a. Remove four bolts and bumper side brace from frame.
Push down clip
Bumper Side
Brace
Bolt
Frame
3 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
b. Remove four bolts and bumper from frame.
2. Steering Shaft
Bolts
Bumper c.
Remove four bolts and splash shield from undercarraige.
Splash
Shield
Bolts
WARNING
Accidental deployment of the air bag can result in serious personal injury or death. To avoid accidental deployment during installation of the lift kit, the Supplemental Restraint System (SRS, or airbag) must remain deactivated. Do not allow anyone near the airbag during installation. Refer to the factory service manual or owner's manual for the recommended procedure to disable the SRS. After kit installation, the SRS must be reactivated before driving the vehicle.
CAUTION
If the following step is not performed, the airbag clockspring could be damaged. Do not turn the steering wheel while the steering shaft is disconnected.
a. Strap steering wheel to prevent accidental movement.
b. Mark the steering intermediate shaft and u-joint coupler as shown.
c.
Remove bolt and intermediate shaft from u-joint coupler.
U-joint
Coupler
Mark Steering Shaft
Intermediate Shaft
Engine Compartment
1. Fresh Air Intake Hose a. Loosen two clamps and remove fresh air intake hose.
Clamps
Bolt
Fresh Air
Intake
Hose
4 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
3. Wire Harness and Line Clips a.
Driver side:
Remove two clips from upper fender well.
Brake
Master
Cylinder d. Remove a/c line clip from upper fan shroud.
A/C Line
Clips
Back of
Battery
Cover b. Remove clip from battery box.
Side of
Battery
Cover
Clip
A/C Line Clip e.
Passenger side:
Remove wire harness from clip and power steering reservoir.
Wire Harness
Clip
Power Steering
Reservoir c.
Remove brake line clip from fender well.
f.
Remove brake line from clip on fender well.
Steering Shaft
Brake Line Clip
Brake Lines
Brake Line
Clip
Brake Line
5 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
g. Remove wire harness and vent hose clip from fender well.
Wire Harness and Vent Hose
Clip b. Remove two bolts and separate condenser from radiator.
Bolts
Condenser
Fender
Well
Power Steering
Reservoir h. Remove a/c line from clip on upper fan shroud.
Remove hose from clip at upper fan shroud.
Fan Shroud
Upper Radiator Hose
A/C Line
Clip
Hose and
Hose Clip
4. Fan Shroud a. Remove bolt and upper radiator center mount bracket from core support and radiator.
Bolt
Radiator
Bracket
Radiator c.
Passenger Side:
Tie condenser to core support with kit
zip tie
as shown.
Kit
Zip Tie
Core Support
Condenser
Core Support
6 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
WARNING
If the engine cooling system is hot, the coolant will be
HOT and UNDER PRESSURE. To prevent serious personal injury, wait until the cooling system is completely cool before removing the cap from the radiator.
d. Remove upper radiator hose from radiator making sure to catch the coolant in a drain pan. Use a kit
zip tie
to hold radiator house out of way.
Place a plastic bag over radiator outlet to keep coolant from leaking.
f.
Remove two bolts from pulley to allow spanner wrench to be used.
g. Remove fan and fan clutch assembly from vehicle using a spanner wrench.
Radiator
Pulley
Bolts
Fan Clutch
Fan h. Remove lower fan shroud and fan shroud ring from vehicle.
Fan Shroud Ring
Radiator
Hose
Hose Clamp
Radiator
Plastic
Bag e. Remove six clips and upper fan shroud from vehicle.
Clips
Upper Fan
Shroud
Radiator Lower Fan Shroud i.
Lift radiator from lower mounting locations and rest on frame making sure to watch all a/c, transmission cooler lines and hoses.
Radiator
Radiator
Lower
Mount
Frame
Condenser
Front of Vehicle
7 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
Underside of Vehicle
1. Ground Strap a. Remove bolt and ground strap from cab passenger side.
b. Remove license plate light wire harness from wire harness connector on rear bumper c.
Remove trailer tow wire harness clip from bumper.
Rear
Bumper
Cab
Ground
Strap
Rear of Vehicle
1. Fuel Filler a. Remove fuel cap, bolt and fuel filler from bed.
Fuel Filler
Wire Harness Connector d.
Driver Side:
Remove five bolts from bumper bracket, frame and bumper.
Bolts
Bolt
Fuel Cap
2. Spare Tire a. Remove spare tire (refer to Owner’s Manual).
3. Rear Bumper a.
Driver side:
Remove wire harness from clip and rear bumper bracket.
Cover
Plate
Plastic Tabs
Bumper
Bolts
Rear Bumper
Bracket
Bumper e.
Driver Side:
Remove cover plate from top of rear bumper by squeezing four plastic tabs.
Frame
Wire Harness
Rear Bumper
Bracket
8 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
f.
Remove two torx bolts and loosen bolt holding brace to bumper. Remove bumper bracket from frame and bumper making sure to support this end.
Torx Bolts
Loosen Bolt
Bumper
Install Kit
Cab
1. Lift cab a. Loosen, but DO NOT remove, cab mounting bolts on driver side (three bolts on vehicles with regular cab; four bolts on vehicles with extended or crew cab).
Cab Mount
(Core Support)
Loosen bolts at these mounts
CAUTION
Use caution when removing the bumper. Make sure not to scratch the truck bed.
g.
Passenger Side:
Remove two bolts from bumper bracket and frame. Remove bumper and bumper bracket from vehicle.
Cab Mount
Frame
Bolts
Rear Bumper
Bracket
Bumper b. Remove bolt and lower bushing from each cab mount on passenger side.
Cab Mounts
Remove bolts from these mounts
Lower
Bushing
Bolt
9 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
d. Install lower bushing and a kit
bolt
(14mm x
200mm) on each cab mount. DO NOT tighten.
WARNING
Use extreme caution when lifting body from frame. To prevent serious personal injury, ensure the lifting device is securely placed. Keep your hands out from between the body and frame.
CAUTION
Continually check hoses, wires, lines, etc. to be sure that everything is flexing properly and not binding, or damage to the vehicle could result. Be especially careful of the a/c hoses at the fire wall, the belt pulley, and at the core support. Ensure brake lines stretch while lifting. Bending the lines to gain ample slack may be necessary. Be extremely careful not to kink the lines.
2. Cab passenger side.
Kit
Block
(3” x 3”)
Upper Factory
Bushing
Lower Bushing a. Using a hydraulic jack and a wooden block, slowly lift passenger side of cab a little more than 3”.
Kit
Bolt
(14mm x 200mm)
3. Cab driver side
WARNING
The kit
blocks
must be installed in addition to the factory upper and lower bushings. Installing the kit
blocks
without the factory upper and lower bushings could result in damage to the vehicle or serious personal injury.
b. Install kit
blocks
(3” x 3”) on upper bushings on each cab mount.
Kit
Block
(3” x 3”)
Upper Factory
Bushing a. Repeat previous steps on driver side of cab.
b. Set cab-to-bed spacing according to previous measurement.
c.
Remove each kit
bolt
(14mm x 200mm), one at a time, and apply a few drops of Loctite® to threads. Install kit
bolt
(14mm x 200mm), kit
washer
(14mm), and lower bushing. Tighten kit
bolt
to
55
ft. lbs.
Kit
Block
(3” x 3”)
Upper Factory
Bushing
Lower Factory
Bushing
Lower Bushing
Kit
Bolt
(14mm x 200mm),
Washer
(14mm) c.
Lower cab onto kit
blocks
(3” x 3”).
10 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
Bed
1. Lift bed a. Loosen, but DO NOT remove, bed mounting bolts on driver side (three bolts on vehicles with short bed; four bolts on vehicles with long bed). b. Install kit
blocks
(3” x 3”) on each frame mount.
Install Kit
Blocks
(3” x 3”) on each Bed Mount
Loosen bolt at these mounts
2. Remove a bolt from each passenger side bed mount.
c.
Lower bed onto kit
blocks
.
d. At each bed mount, install a kit
bolt
(12mm x
140mm). DO NOT tighten.
Remove bolt from these mounts
Kit
Block
(3” x 3”)
Kit
Bolt
(12mm x 140mm)
WARNING
Use extreme caution when lifting the bed from the frame. To prevent serious personal injury, ensure the lifting device is securely placed. Keep your hands out from between the bed and frame.
CAUTION
To prevent damage to the vehicle while lifting the bed, continually check hoses, wires, brake lines, etc. to ensure everything is flexing properly and not binding.
Ensure clearance between bed and cab is maintained.
3. Bed passenger side.
a. Using a hydraulic jack and a wooden block, slowly lift passenger side of bed a little more than 3”.
NOTE
It may be necessary to lift the back of the bed slightly to allow the two rear bed mount bolts to be installed.
e. Repeat previous steps on driver side of bed.
f.
Set bed-to-cab spacing according to previous measurement.
g. Remove each kit
bolt
(12mm x 140mm), one at a time, and apply a few drops of Loctite® to threads. Install kit
bolt
(12mm x 140mm) and kit
washer
(7/16”). Tighten kit
bolt
to
55
ft. lbs.
11 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
Rear of Vehicle
1. Spare Tire a. Mark and cut rear crossmember above existing hole as shown.
b. Remove two torx bolts and loosen bolt holding brace to bumper. Remove three bolts and rear bumper bracket from bumper.
Loosen Bumper
Brace Bolt
Two Torx
Bolts
Mark Rear
Crossmember
Cut Rear
Crossmember
Bolt
2. Rear Bumper
WARNING
The following procedure is intended only to enhance the appearance of the vehicle. The rear bumper will no longer be rated for towing of any kind. Towing with the rear bumper after it has been lifted can result in death, serious personal injury, or damage to the vehicle. Towing after the bumper has been lifted should be accomplished using a rated Class III receiver type hitch.
a.
Passenger Side:
Remove cover plate from top of rear bumper by squeezing four plastic tabs.
c.
Install two kit
Kit
Bumper
Bracket,
Left rear bumper brackets
with four factory bolts. Do Not Tighten.
on frame
Cover
Plate
Plastic Tabs
Bumper
Bolts
12 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
g.
Vehicles with hitch:
Remove two plastic pads from frame above rear tires.
CAUTION
Use caution when installing the bumper making sure not to scratch the truck bed.
d. Install bumper on two kit
rear bumper brackets
with six kit
bolts
(3/8” x 1”), six kit
washers
(3/
8”), and four factory bolts on bottom.
Plastic Pad
Location
Frame
Tire
Bumper
Kit
Bolts
(3/8” x 1”), kit
washers
(3/8”)
Kit
Bumper
Bracket
Plastic Pad h. Install two plastic pads, removed from bed mounting locations, into kit
bumper to hitch bracket.
Holes may require enlarging.
Factory
Bolts
Kit
Bumper to
Hitch Bracket
Plastic Pads
Plastic Pads e. Align bumper to bed clearance and tighten all mounting bolts.
f.
Install cover plates on top of rear bumper.
Bumper
Cover
Plates i.
Install two kit shown.
U-nuts
to underside of bumper as
Kit
j-nut Clips
Rear Bumper
Under Side
13 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
j.
Install two kit
bolts
(5/16” x 1”), and kit
bumper to hitch bracket
on vehicle.
c.
Cut two fuel filler metal lines as shown.
Kit
Bumper to
Hitch Bracket
k.
Install trailer tow wire harness clip on bumper.
3. Fuel Filler
Hose (1” x 4”)
WARNING
Use extreme caution when working near the fuel lines and the fuel tank. Clean up spilled fuel immediately. A spark could cause an explosion or fire resulting in serious personal injury and property damage.
a. Remove bolt and ground strap from frame.
Ground Wire
Bolt
Frame
Hose Clamps
Cut Fuel Filler
Metal Lines d. Install two kit
hose clamps # 20
, and kit
hose
(1” x 4”) on large filler line. Install two kit
hose clamps # 6
and kit
hose
(1/4” x 4”) on smaller fuel line.
Hose (1/4” x 4”) Hose Clamps e. Install a kit
bracket, ground strap
on frame with bolt. Install ground strap on kit
bracket, ground strap
with a kit
washer
(1/4”) and kit
nut, nylock
(1/4”).
b. Remove hose clamp, fuel clip and fuel filler from hoses and vehicle.
Ground Wire
Nut and
Washer, 1/4”
Ground Strap
Bracket
Fuel Filler
Fuel Clip
Hose Clamp
14 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
Inside Cab
1.
Manual Transmission:
Shift Lever a. Unscrew shift knob from shift lever.
b. Release clips and remove shift boot from shift lever.
c.
Remove center console from floor.
d. Remove bolts and shift cover from floor.
e. Remove four bolts holding shift lever to transmission.
Shift Knob
Shift Boot
Center Console
Bolts
Shift Cover h. Scribe a line along the side of the shift lever
(below the lowest bend) as shown. Cut the lever into two pieces through the line and deburr as necessary.
Scribe Line
Shift Lever i.
Scribe a line along length of kit
shift extension.
j.
Weld both halves of shift lever to kit
shift extension
making sure to align the scribed lines of all pieces.
k.
Assemble the shift lever in reverse order of disassembly.
Underside of Vehicle
1. Ground strap a. Install bolt and ground strap on cab.
f.
Slide grommet, inner boot, and mounting plate off shift lever.
g. Remove plastic retainer from ball socket on shifter.
Shift Lever Plastic Retainer
Ground
Strap
Grommet
Inner Boot
Mounting Plate
Bolt
Engine Compartment
1. Steering shaft.
WARNING
Verify the steering extension is securely installed as specified in the instructions. Failure to do so may cause steering malfunction, resulting in property damage or serious personal injury.
15 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
a. Remove bolt and steering intermediate shaft from rack and pinion and vehicle.
Bolt d. Install lower intermediate shaft on the rack and pinion.
e. Apply a few drops of Loctite® to factory bolt and tighten bolts to 33 lb.-ft.
2. Radiator
Intermediate
Shaft
Rack and Pinion a.
Passenger Side:
Trim two sections from lower radiator support as shown.
Passenger Side Lower Support - from Top
Trim along line b. Install female end of kit
steering extension
on male end of intermediate shaft. Place a few drops of Loctite on threads of kit
bolt.
Tighten kit
bolt
(3/8” x 1
1/4
” Allen head) to 30 ft-lbs.
Lower Radiator Support
Modified Lower Radiator
Support
Intermediate Steering
Shaft
Kit
Bolt
Kit
Steering Extension
c.
Install kit
steering extension
and intermediate shaft making sure kit
steering extension
is installed on the upper steering shaft. Align marks on steering intermediate shaft and upper shaft.
Kit
Steering Extension
Passenger Side Lower Support - from Bottom
Modified Lower
Radiator Support
Trim along line
Upper Steering
Shaft
Marks
Steering Intermediate
Shaft
16 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
b.
Driver Side:
Trim lower radiator support bracket as shown.
Driver Side Lower Support - from Top
Trim along lines
Lower Radiator
Support Bracket
CAUTION
When performing the radiator installation, make sure the studs on the two radiator brackets, installed in the next step, do not puncture the condenser while maneuvering the radiator into position.
d. Place a few drops of Loctite on threads of kit
screws.
Install two kit
screws
and kit
bracket,
3” radiator drop down
as shown.
CAUTION:
Watch studs on bracket do not puncture the condoner when positioning radiator.
Kit
Screws
Modified Lower Radiator
Support Bracket
Driver Side Lower Support - from Bottom
Modified
Lower Radiator Support
Bracket
Kit
Radiator Drop
Down Bracket
e. Place kit
bracket, lower radiator
on lower radiator mount grommets.
Trim along lines c.
Install two kit
U-nuts
on kit
brackets, radiator drop down
.
Kit
U-Nuts
Kit
Radiator
Bracket
Radiator
Grommet
Kit
Radiator Drop
Down Brackets
17 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
f.
Passenger Side:
Install kit
brackets, radiator drop down
with kit
washers
(1/2” thick), kit
washer
(5/16”), and kit
bolt
(5/16” x 1 1/4”) below radiator support bracket making sure kit
bracket
is pushed forward as far as possible.
Passenger Side Lower Support - from Top
Frame
Lower Radiator
Support
Kit
Bolt
&
Washer
Forward g.
Driver Side:
Install kit
brackets, radiator drop down
with kit
washers
(1/2” thick), kit
washer
(5/16”), and kit
bolt
(5/16” x 1 1/4”) below radiator support bracket making sure kit
bracket
is pushed forward as far as possible.
Driver Side Lower Support - from Top
Frame
Lower Radiator Support
Kit
Bolt
&
Washer
Passenger Side Lower Support - from Bottom
Lower Radiator
Support
Kit
Radiator Drop
Down Bracket
A/C Line
Driver Side Lower Support - from Bottom
Lower Radiator
Support
Kit
Radiator Drop
Down Bracket
Forward h. Remove kit
zip tie
from condenser and body.
i.
Install condenser on two kit
drop down bracket studs
(3”) with two kit
washers
(1/4”) and two kit
nylock nuts
(1/4”). DO NOT TIGHTEN.
Driver Side Kit
Drop
Down Bracket
Passenger Side Kit
Drop Down Bracket
18 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
Condenser
Wood
Drill
Passenger Side
Mark and
Drill Holes
Condenser
WARNING
Failure to use a block of wood behind the condenser will cause damage to the radiator. Performance Automotive Group will not be responsible for radiator damage.
j.
Mark and drill two 1/4” holes in condenser and body as shown using a block of wood to prevent drill from puncturing lines.
Driver Side
k.
Install studded end of two kit
drop down brackets
(2”) on condenser with two kit
washers
(1/
4”) and two kit
nuts
(1/4”).
l.
Install kit
drop down brackets
(2”), and condenser to body with two kit
bolts
(1/4” x 1”), four kit
washers
(1/4”), and two kit
nuts
(1/4”).
Mark and
Drill Holes
Condenser
Kit
Bolt, Washers,
and
Nut
Kit
Drop Down
Bracket
Kit
Washer
and
Nut
m. Tighten kit
nuts
(1/4”) on kit
radiator drop down brackets
(3”).
n. Install kit
upper radiator bracket
on core support and radiator with bolt.
Bolt
Kit Upper Radiator
Bracket
19 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
3. Fan Shroud a. Place lower fan shroud and ring shroud on radiator.
Fan Shroud Ring Lower Fan Shroud e. Place over flow hose on passenger side upper fan shroud clip.
f.
Place a/c line in passenger side fan shroud clip.
Fan Shroud
Upper Radiator Hose
A/C Line
Clip
Hose and
Hose Clip
Radiator b. Install fan clutch and fan on vehicle. Install two pulley bolts.
Radiator
Pulley
Bolts
Fan Clutch
Fan
4. Air Box a. Remove two bolts from passenger side of engine mounted air intake box.
c.
Install upper fan shroud to lower fan shroud with six clips.
Clips
Bolts
Air Intake
Box b. Remove two u-nut clips from intake.
Upper Fan
Shroud
Air Intake
Box
U-Nut Clips
Intake d. Install upper radiator hose to radiator
20 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
c.
Install two kit
spacers
(1” tube), two kit
bolts
(1/
4” x 3”), four kit
washers
(1/4”), and two kit
nylock nuts
(1/4”).
Kit
Bolts, Washers
, and
Nuts
a. Remove two outer push clips, eight air dam clips and lower air dam from lower fascia.
Lower
Fascia
Push Clip
Kit
Spacers
d. Install intake hose to air box and engine mounted air intake box with two clamps.
Clamps
Air Box
Air Dam Air dam Clips b. Trim front bumper lower fascia, to clear frame horns, as shown.
Mark Front Lower Fascia
Fresh Air
Intake
Hose
Front of Vehicle
1. Front Bumper
Trim Front Lower Fascia c.
Install four kit
mini blocks
(3” x 2”), bumper, four kit
washers
(5/16”), and
bolts
(10mm x 100mm) on front of vehicle. Place a few drops of Loctite on threads of kit
bolts.
21
Kit
Blocks
(3” x 2”)
Kit
Blocks
(3” x 2”)
2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
d. Install kit
side bumper support brackets
with four bolts, four kit
bolts
(7/16” x 1 1/2”), eight kit
washers
(7/16”), and four kit
nylock nuts
(7/
16”) on bumper and frame. Place a few drops of
Loctite on threads of bolts.
Kit
Bolts, Washers,
and
Nuts
Kit
Side Bumper
Bracket
Bed e. Position air dam on lower front fascia and mark locations to be cut as shown.
necessary to remove the plastic pads from frame before installing kit
Bed
Kit
Bed
Spacer
Rear Tire
Kit
Bed
Spacer
Bed
Kit
Bolt
&
Washer
Frame
bed spacers
.
Mark and Cut
After Completing Installation
Engine Compartment
1. Install airbag fuse and fuse block cover.
f.
Install lower air dam on lower front fascia.
Bed Spacers
1. Install two (four on vehicles with standard cab or extra cab) kit
bolt
(5/16” self tapping), kit
washers
(5/16” USS) and kit
bed spacers
to frame. It may be
Fuse Cover
Fuse Box
22 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
2. Battery cables.
ranges. Check battery connections and electrical component operations.
a. Connect both battery cables. Connect positive cable first, then negative cable.
Positive
Cable
Negative
Cable
Final Installation Notes
1. Apply kit
label
(warning) to dashboard in plain sight of all vehicle occupants.
2. Check all fasteners to ensure they are tight.
3. Ensure all wires, hoses, cables, etc. are properly connected and there is ample slack.
WARNING
If the engine cooling system is hot, the coolant will be
HOT and UNDER PRESSURE. To prevent serious personal injury, wait until the cooling system is completely cool before removing the cap from the radiator.
4. Remove radiator cap and fill radiator with engine coolant.
WARNING
Retorque all fasteners after 500 miles and after off road use. All body lift components should be visually inspected and fasteners retorqued during routine vehicle servicing.
CAUTION
Performance Automotive Group does not recommend any particular wheel and tire combinations for use with its body lifts and cannot assume responsibility for the customer’s choice of wheels and tires. Refer to your owner's manual for recommended tire sizes and warnings related to the use of oversized tires. Larger wheel and tire combinations increase stress and wear on steering and suspension components, which leads to increased maintenance and higher risk for component failure. Larger wheel and tire combinations also alter speedometer calibration, braking effectiveness, center of gravity, and handling characteristics. Consult an experienced local off road shop to find what wheel and tire combinations work best with your vehicle.
NOTE
All warranty information, instruction sheets, and other documents regarding the installation of this product must be retained by the vehicle owner. Information contained in the instructions and on the warranty card will be required for any warranty claims. The vehicle owner needs to understand the modifications made to the vehicle and how they affect vehicle handling and performance. Failure to provide the customer with this information can result in damage to the vehicle and severe personal injury.
Rev. 01, Copyright 12/04 Performance Automotive
Group
5. Start engine and top off engine cooling system.
Purge air from cooling system according to manufacturer’s instructions.
6. Install radiator cap.
Dynamic Vehicle Check
1. Test-drive vehicle. Check steering in both directions to ensure that there is no binding. Check operation of clutch, brake system, and parking brake. Check operation of transmission and transfer case. Ensure there is full engagement in all gears and 4WD
23 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
Kit Parts List
Qty.
Description
Kit 10153
4
Block
, 3" x 2" Mini Block
6
Block
, 3" x 3" Lift
8
Block
, 3" x 3" Lift w/ 5/8" Hole
4
Block
, Crush 3" x 2"
2
Bolt
, 1/4" x 1"
2
Bolt
, 1/4" x 3"
4
Bolt
, 10mm x 100mm
6
Bolt
, 12mm x 1.75 x 140mm
8
Bolt
, 14mm x 2.00 x 200mm
4
Bolt
, 5/16" Self Tapping
2
Bolt
, 5/16" x 1 1/4"
2
Bolt
, 5/16" x 1"
4
Bolt
, 7/16" x 1 1/2"
6
Bolt
, 3/8" x 1"
2
Bracket
, Bumper Support
1
Bracket
, Bumper to Hitch Cover Rear
1
Bracket
, Lower Radiator Support Left
1
Bracket
, Lower Radiator Support Right
2
Bracket
, Radiator 2"
2
Bracket
, Radiator 3"
1
Bracket
, Radiator Offset 2" w/stud
1
Bracket
, Rear Bumper Left
1
Bracket
, Rear Bumper Right
1
Bracket
, Upper Radiator Support
2
Clamp
, Hose # 20
2
Clamp
, Hose # 6
1
Extension
, Shift
1
Extension,
Steering
1
Hose
, Fuel Filler 1" x 4"
1
Hose
, Fuel Filler 1/4" x 4"
9
Nut
, 1/4" Nylock
4
Nut
, 7/16" Nylock
2
Screw
, 6mm x 2.0 Tappered
2
Spacer
, 1" x .671OD x .5ID
4
Tie
, Zip
4
U-Nut
5/16"
2
Washer
, 1/2" thick
18
Washer
, 1/4"
8
Washer
, 14mm
8
Washer
, 5/16" USS
14
Washer
, 7/16"
6
Washer
, 3/8"
Steering Extension
NOTE
Depending on the vehicle configuration (automatic or manual transmission, 2WD or 4WD, cab length, bed length, etc.), some parts may not be used.
Accessories
(Available After 3/1/05)
The following accessories are also available:
Kit # 83300:
Pre-Runner Front Bumper
Kit # 83400:
Pre-Runner Rear Bumper
Kit # 84300:
Side Bars
Kit # 86300:
Pre-Runner Spare Tire Carrier
24 2004-05 Chevy/GMC Colorado/Canyon - Kit 10153
