Installation Instructions
Contents
1. 4 Disconnect the ground wire located on the top of the frame rail near the front of the driver side inner fender well 5 Make an indexing mark on the steering shaft and disconnect it to prevent binding during the body lift procedure Ensure the steering wheel is not turned while disconnected gt gt Front Fascia DISASSEMBLY 6 Remove the bolts securing the front grill and facia to the core support See Figure 1 Figure 1 L Remove the bolt connecting the support strut to the front bumper corner support See Figure 2 Figure 2 C1257 Installation pg 5 C1257 Installation pg 6 8 On both sides remove the front 7 screws mounting the inner fender to the front bumper and fender and pull the fender rearwards to gain access to the outer fascia to fender mounting bolts See Figure 3 Figure 3 9 Remove the 3 outer facia bolts on each side See Figure 4 Figure 4 10 Disconnect the fog lights 11 Remove the 2 screws on the bottom of the facia mounting to the frame on each side of the front splash guard 12 Remove the 2 center fascia mounting bolts See Figure 5 Figure 5 13 Gently pull out on the front fascia near the inside lower corner of the headlights to release the clips and remove the facia from the vehicle 14 Remove the 2 bolts per side mounting the front crash bar to the frame See Figure 6 Figure 6 gt gt PARKING Brake BRACKET 15 Locate the parking brake running al2. C1257 Installation Instructions 2015 Chevy Colorado GMC Canyon OFFROAD PRODUCTS 2 3 4 Combo Kit Read and understand all instructions and warnings prior to installation of product and operation of vehicle 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 PRODUCT SAFETY WARNING Certain Zone Suspension Products are intended to improve off road performance Modifying your vehicle for off road use may result in the vehicle handling differently than a factory equipped vehicle Extreme care must be used to prevent loss of control or vehicle rollover Failure to drive your modified vehicle safely may result in serious injury or death Zone Offroad Products does not recom mend the combined use of suspension lifts body lifts or other lifting devices You should never operate your modified vehicle under the influence of alcohol or drugs Always drive your modified vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions Always wear your seat belt Difficulty Level T
3. ECHNICAL SUPPORT easy Q 3 4 5 difficult Live Chat provides instant communication with Zone tech support Anyone can access live Estimated installation 5 hours chat through a link on www zoneoffroad com Special Tools Required www zoneoffroad com may have additional information about this product including the lat 4 5 Cut off wheel est instructions videos photos etc Send an e mail to tech zoneoffroad com detailing your issue for a quick response Torx socket set 888 998 ZONE Call to speak directly with Zone tech support hin req d for 275 or 285 width tires Tire Wheel Fitment Special literature required OE Service Manual for model year of vehicle Refer to 285 70R17 32 7 x 11 2 or equiv manual for proper disassembly reassembly procedures of OE and related components With stock backspacing PreE INSTALLATION NOTES _ 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 bloc
4. ame using the factory bolts Ensure the spare bolt pack 285 tire winch tubes line up while sliding on the bumper Torque the bolts to 60 ft lbs 42 Reconnect the wire harness and clips disconnected for the bumper removal gt gt Front Fascia INSTALLATION 43 On both sides using the new front bumper brackets as a template cut the material shown in the figure from the frame Also drill a 7 16 hole at the inside bracket mounting hole See Figure 14 C1257 Installation pg 11 C1257 Installation pg 12 Figure 14 44 Using the provided 10mm flat head bolt in the outside upper hole and the socket head bolt in the lower hole attach the bumper brackets to the frame See Figure 15 Figure 15 45 Attach the crash bar to the bumper brackets using the provided 3 8 bolts nuts and washers 46 Remove the front tow hooks and flip the tow hooks over and reinstall them with the hardware going from the outside in Torque bolts to 60 ft lbs Reinstall foam covers See Figure 16 Figure 16 47 Remove the 2 lower facia mounting brackets and transfer the clips to the new provided brackets Step 47 Note 48 Install the lower facia brackets to the facia with the OE clips using the original screws See Figure 17 If you plan on removing the lower bumper valance it is recommended to do it with the facia removed for the easiest bolt access Figure 17 49 Install the facia back onto the vehicle first by engagi
5. and install the bed spacer and body blocks similar to the passenger side 33 Torque the bed mount bolts to 60 ft lbs 2 gt REAR Bumper BRACKET INSTALLATION 34 Unplug the trailer wire harness and 2 additional plugs that will prevent the bumper from being removed as shown See Figure 9 Step 30 Note Bed lift hardware is located in bolt pack 284 Step 31 Note Bed spacer hardware is located in bolt pack 285 C1257 Installation pg 9 C1257 Installation pg 10 Figure 9 35 Remove the 2 bolts on the outside of each frame rail and slide the bumper off of the vehicle 36 Release the clips on the bumper cover enough to access the bolts to the bumper brackets Remove the bumper brackets from the bumper by removing the 6 bolts See Figure 10 Figure 10 37 Remove the factory U nuts from the factory brackets and transfer them to the provided brackets See Figure 11 Figure 11 38 Install the new bumper brackets in place of the factory brackets using the factory hardware Tighten bolts to 60 ft lbs See Figure 12 Figure 12 39 Place the provided step spacer above the factory hitch The slots cut in the tube face up and towards the front of the vehicle See Figure 13 ii Figure 13 40 Fasten the step spacer to the hitch with the provided 3 8 x 3 4 bolts nuts and Step 40 Note washer using the outermost holes Bed Step hardware is located in 41 Re install the bumper onto the fr
6. and level surface Block the rear wheels for safety the wheel opening 2 Measure the ride height of the vehicle from the center of the wheel to the fender and record 3 Raise the front of the vehicle with a hydraulic jack Support the frame rails with jack stands gt gt INSTALLATION INSTRUCTIONS l Remove the front wheels 2 Remove the sway bar links from the vehicle They are attached with a through bolt Save all components for re installation Figure 1 Figure 1 N C1257 Installation p i Perform the following installation steps on one side at a time 3 Disconnect the brake line bracket from the strut tower and the ABS wire from the control arm mount to gain additional slack Figure 2 Figure 2 4 Support the lower control arm with a hydraulic jack and remove the 3 upper nuts holding the top of the strut to the frame mount DO NOT remove the center nut on the strut Discard nuts these will not be re used Figure 3 Figure 3 5 Remove the lower strut bolt Figure 4 Figure 4 C1257 Installation pg 3 Step 6 Note Be prepared to support the knuckle once the upper balljoint is removed C1257 Installation pg 4 10 11 12 13 14 Remove the upper ball joint nut and thread it on until flush with the end of the ball joint Gently strike the end of the ball joint to dislodge it from the knuckle it typically does not take much force Avoid hitting the aluminum knu
7. ce a jack with a block of wood to distribute the load near the front cab mount in a reinforced area of the body and lift the body just high enough to place the provided 3 diameter body blocks between the OE mount and the body 25 Apply Loctite to the new bolts and thread them a few turns into the body 26 Lower the jack and remove the bolts from the driver side Raise the driver side and make sure there 1s adequate slack on all wires and cables as the body is lifted 27 Install the remaining cab bolts with the factory washers and Loctite Lower the jack and torque all cab bolts to 100 ft lbs A gt 22 BED LIFT M E Ensure the cab lift procedure is performed before raising the bed to avoid any interfer ence between the bed and the body 28 Remove the 4 bed mount bolts on the passenger side of the vehicle Loosen but do not remove the driver side bolts 29 Locate the jack towards the passenger side on one of the bed supports and raise the bed enough to install the 2 diameter body lift pucks at each location 30 Apply Loctite and loosely install the provided 12mm x 70mm bolts and washers at the bed mounts 31 Remove the pad from the frame rail bed supports and place it on the provided steel tube bed spacer Using the self tapping 5 16 bolt fasten the bed spacer to the frame Do no overtighten the bed will hold the block in place once the mounts are torqued See Figure 8 32 Remove the driver side bed mount bolts
8. ckle Disconnect the ball joint and allow the knuckle to swing rearward out of the way Figure 5 Figure 5 Using the jack lower the control arm and knuckle enough to remove the strut Install the strut spacer onto the factory upper strut studs Figure 6 Figure 6 Loosely re install the strut with strut spacer to the frame with the provided 10mm locking flange nuts Raise the lower control arm and re connect the upper ball joint to the knuckle Re install the lower strut bolt but do not tighten Torque the upper ball joint nut to 55 ft lbs Torque the upper strut mount nuts to 45 ft lbs Complete the strut spacer installation procedure on the other side Reattach the sway bar links to the sway bar and lower control arms and tighten until the bushings begin to swell Re install the brake line brackets and ABS wire clips to the frame gt gt Post INSTALLATION l Install the tires and lower the vehicle to the ground bounce the front end to settle the suspension Torque the lower strut bolt to 125 ft lbs A front end alignment must now be performed to original equipment specifications BODY LIFT INSTALLATION INSTRUCTIONS l Park the vehicle on a clean flat surface and block the rear wheels for safety 2 Disconnect the positive and negative battery cables 3 Disconnect the clips holding the electric harness located behind the driver s side inner fender and above the front cab body mount to gain adequate slack
9. k 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 1s a base figure Final ride height dimensions may vary in accordance to original vehicle attitude Always measure the attitude prior to beginning installation Kit Contents Important Verify you have all of the kit components before beginning installation STRUT SPACER CONTENTS Qty Part Strut Spacer Weld on Steering Stops Bolt Pack 6 10mm Flange Nut Bopy Lirt Kit CONTENTS Qty Part 3 Diameter body block 2 Diameter body block Front Bumper Bracket Lower Facia Bracket Drv Lower Facia Bracket Pass Rear Bumper Bracket Drv Parking Brake Bracket Parking Step Spacer Loctite 8 3 8 x 18 Zip Tie Bolt Pack 284 8 14mm x 140mm bolt 8 12mm x 70mm bolt 9 16 SAE flat washer 8 1 2 SAE flat washer Bolt Pack 285 3 8 16 x 3 4 bolt 3 8 16 x 1 bolt 3 8 SAE washer 3 8 16 lock nut 10mm x 30mm flat head bolt 10mm x 30mm SHCS 7 16 14 x 1 bolt 7 16 SAE washer 7 16 14 lock nut 5 16 18 x 1 2 self tapping bolt Rear Bumper Bracket Pass Important measure STRUT SPACER INSTALLATION INSTRUCTIONS before starting Measure from the center of the gt gt PRE INSTALLATION wheel up to the bottom edge of L Park vehicle on clean
10. n Warnings gt Fina STEPS 1 Check all fasteners for proper torque Check to ensure for adequate clearance between all 61 Double check all hoses wires cables etc for proper slack clearances and rotating mobile fixed and heated routing members Verify clearance between exhaust and brake lines fuel lines fuel tank floor boards and wiring 63 Check for proper tire clearances harness Check steering gear for l Test and 1 t brak 64 Check hardware after 500 miles ee est and inspect brake 60 Reconnect the battery 62 Check all hardware for proper torque 2 Perform steering sweep to ensure front brake hoses have adequate slack and do not contact any rotating mobile or heated members Inspect rear brake hoses at full extension for adequate slack Failure to perform hose check replacement may result in component failure 3 Perform head light check and adjustment 4 Re torque all fasteners after 500 miles Always inspect fasteners and components during routine servicing C1257 Installation pg 15
11. ng the clips located near the lower inside corner of the headlights 50 Reinstall the 3 bolts connecting the fender to the fascia on each side 51 Reinstall the 2 center bolts removed in step 12 52 Install the original lower bolts through the new lower facia brackets into the frame 53 Reinstall the inner fender screws 54 Reinstall the outer support brace bolts 55 Reinstall the 6 top screws mounting the grill to the core support gt gt Fina Bopy Litt STEPS 56 Reconnect the ground strap at the driver side frame rail It may be necessary to permanently release it from a retaining clip to gain enough slack 57 Reconnect the steering sector shaft using the factory bolt and Loctite Torque the bolt to 45 ft lbs 58 Using the supplied wire ties attach the electrical harness to the parking brake bracket and frame rail Re use the OE mounts as shown See Figure 18 C1257 Installation pg 13 C1257 Installation pg 14 Figure 18 gt gt OPTIONAL WELD ON STEERING STOPS 59 Included are optional weld on steering stops These can be welded to the lower control arm to eliminate rubbing or eliminate any interference issues that my be present at full steering lock with 275 or 285 width tires Disconnect the battery prep lower control arm for welding weld steering stop onto the lower control arm as shown Coat with paint when completed See Figures 19a 19b Figure 19a Figure 19b Post Installatio
12. ong the driver side frame rail Take a measurement or mark on the cable the current brake adjustment based on the amount of threads showing past the adjustment nut See Figure 7A C1257 Installation pg 7 Step 23 Note Cab mount hardware is located in bolt pack 284 Step 24 Note Ensure there is adequate slack in all cables are wires as the body is lifted C1257 Installation pg 8 Figure 7A 16 Remove the nut and disconnect the parking brake at the rear distribution block 17 Using a flat screwdriver release the clips holding the parking brake cable to the body mount on the frame 18 Remove the cable from the body mount and relocate the cable above the frame 19 Measure down from the center of the OE cable hole on the body mount 1 and drill a 3 8 hole at the mark 20 Install the parking brake bracket with the provide 7 16 hardware so the tab in the bracket lines up with the drilled hole Figure 7B 21 Clip the cable to the hole in the bracket and route it through the center body mount similar to original setup and reconnect the cable at the distribution block Adjust the cable to the setting previously measured gt gt Cas LIFT 22 Starting on the passenger side remove the 3 cab mount bolts and 1 front core support mount bolt Loosen but do not remove the driver side bolts 23 Remove the large factory washers from the bolts and place them on the provided 14mm x 140mm bolt with washers 24 Pla
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