Installation Instructions
Contents
1. Remove the four bolts from the bottom center of the front bumper cover Figure 3 Save bolts Remove the front bumper cover from the vehicle by pull ing straight forward C9212 Installation pg 3 C9212 Installation pg 4 Figure 3 7 Remove the two one per side plastic clips and two bolts holding the inner fender to the bumper Figure 4 Save clips and bolts Figure 4 8 Remove the two bumper mounting bolts and remove the bumper from the ve hicle Figure 5 Figure 5 9 Remove the bolts mounting the tow hooks to the bumper Figure 6 These cannot be reinstalled after the bumper is relocated 10 Remove the plastic shroud from the inside of the bumper Figure 6 It will not be reused Figure 6 gt gt UNDER Hoop 11 Remove the two bolts and two nuts mounting the electrical module to the driver s side of the engine Figure 7 Pull the module free of the mounting studs and allow it to rest out of the way Save nuts and bolts Figure 7 12 Disconnect wire harness Figure 8 from retaining clip on the driver s side middle of inner fender C9212 Installation pg 5 C9212 Installation pg 6 Figure 8 13 Loosen the hose clamp and disconnect the air intake tube from the engine Figure 9 14 Remove the plastic clips from the plastic core support cover Figure 10 Remove the cover from the core support Save cover and clips Figure 10 15 Lock the steering wheel2. Torque 3 8 and 10mm hardware to 30 ft lbs Reinstall the spare tire in the vehicle 68 69 70 71 Figure 34 Check all hardware for proper torque Reattach battery cables Check hardware after 500 miles x 1 1 4 bolt nut and 5 16 USS washer BP 222 Leave loose Also loosely attach the other portion of the winch back in its original location on the frame crossmember with the OE hardware Post Installation Warnings 1 Check all fasteners for proper torque Check to ensure for adequate clearance between all rotating mobile fixed and heated members Verify clearance between exhaust and brake lines fuel lines fuel tank floor boards and wiring harness Check steering gear for clearance Test and inspect brake system 2 Perform steering sweep to ensure front brake hoses have ade quate slack and do not contact any rotating mobile or heated mem bers Inspect rear brake hoses at full extension for adequate slack Failure to perform hose check replacement may result in compo nent failure Longer replacement hoses if needed can be purchased from a local parts supplier 3 Perform head light check and adjustment 4 Re torque all fasteners after 100 miles Always inspect fasten ers and components during routine servicing C9212 Installation pg 19
3. C9212 Installation Instructions 2002 2009 Trailblazer Envoy 2 4wd 2 Body Lift Kit OFFROAD PRODUCTS 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 Propuct 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
4. battery back up at this time a el ke ATS ae hik hy om f i 3 f k 3 i G z a F En M 7 A f i m A F sh Ee i I a A E m ai 1 r ra Ld i gt Figure 21 36 Reattach the air intake hose to the intake and tighten the factory hose clamp securely C9212 Installation pg 11 37 Step 37 38 Note Radiator bracket hardware is located in hardware pack 219 The provided radiator brackets 38 are driver s and passenger s side specific 39 40 Locate the four core support bolts two per side near the upper corners of the radiator Working on one side at a time remove the two bolts and install the provided radiator brackets with 8mm x 45mm bolts and 5 16 USS washers Leave hardware loose The bracket should run down toward the radiator and to the inside of the vehicle Figure 22 With both radiator brackets loosely installed position a provided urethane stem bushing in the radiator flange hole located just under the bracket The lip of the bushing will fit snug down into the hole Fasten the bracket and bushing to the radiator with a 3 8 x 1 1 4 bolt nut and 5 16 USS washers Tighten the 3 8 hardware until the bushing begins to swell Figure 22 Go back and torque the 8mm bolt to 22 ft lbs Figure 22 In some cases the radiator overflow hose may need to be clamped out of the way after the radiator is relocated A clamp is provided in hardware pack 219 to do this and can be mounted
5. easy 1 2 G 4 5 difficult TECHNICAL SUPPORT Estimated installation 4 6 hours Live Chat provides instant communication with Zone tech support Anyone can access live Special Tools Required chat through a link on www zoneoffroad com Reciprocating saw and or cutoff www zoneoffroad com may have additional information about this product including the lat tool est instructions videos photos etc p Tire Wheel Fitment Send an e mail to tech zoneoffroad com detailing your issue for a quick response 888 998 ZONE Call to speak directly with Zone tech support 30 x 9 50 Tire on stock wheel PreE INSTALLATION NOTES pd Special literature required OE Service Manual for model year of vehicle Refer to manual for proper disassembly reassembly pro cedures of OE and related components 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 combina tions larger than OE consider the additional stress you could be inducing on the OE and related components 4 Secure and properly block vehicle prior to installation of Zone Offroad Products Always wear safety glasses when using power tools 5 Zone Offroad Products body lifts are designed to be used on vehicles in good operating condition It is not recommended that body lifts be used on vehicles in poor phy
6. two factory holes with the bracket Mark the new holes to be drilled remove bracket and drill to 1 2 at each mark Figure 31 56 IJ 58 Figure 31 Place bumper brackets onto rear bumper Align bumper bracket with bottom of bumper One existing hole will line up on the bottom and the original mounting hole with a 16mm nut will line up with bracket Figure 32 Drill the existing lower hole out to 1 2 Mark and drill the other hole on the bot tom of the bracket to 1 2 Figure 32 L gt Pa A E pr Be i MP ae ad pi 1 pat erf ef ri AT Figure 32 Feed the provided 2 fish wire through the bracket and holes that were just drilled out through the end of the bumper tube Thread a provided 1 2 bolt tab on the fish wire and pull it through the bracket Figure 33 Loosely fasten the bolt tab with a 2 SAE flat washer lock washer and non locking nut Repeat procedure for the three remaining holes Step 56 Note Place a 5 8 SAE washer BP 222 between bumper and bracket when marking holes this will compen sate for frame rail thickness Step 58 59 60 Note All rear bumper hardware is located in hardware pack 222 C9212 Installation pg 17 Step 65 66 Note Spare tire winch hardware is located in hardware pack 222 C9212 Installation pg 18 59 60 61 Figure 33 Loosely install the factory 16mm bolt with a provided 5 8 washer betwee
7. 16 Separate the top and bottom sections of the steering shaft dust boot to expose the universal joint Remove the bolt attaching the top and bottom sections of the steering shaft Figure 11 Mark the two halves of the shaft for realignment and disconnect the top shaft from the bottom Save bolt Figure 11 gt gt REAR 17 Lower the spare tire remove it from the vehicle and set it out of the way See owner s manual for proper spare tire removal procedure 18 Disconnect the trailer wiring harness from the rear bumper hitch Figure 12 Figure 12 19 Remove the four bottom rear bumper cover retaining clips Figure 13 Save clips Step 17 Note Check for proper spare tire winch operation These winch assem blies are known for poor quality breakage if not used and lubricated regularly C9212 Installation pg 7 C9212 Installation pg 8 Eart Aike if hha at 4 ns ra pie MATIE Dl l beh EA ld po a a celawoeT as eee a AT Let te BEEN yin oy Sry Ale ees eT ze i qy ERETT hek 4h ja Aii Figure 13 20 Remove the two screws hold each side of the bumper cover to the rear fenders Figure 14 Save screws Figure 14 21 Open the rear tailgate and remove the seven screws mounting the bumper cover to the body Figure 15 Save screws Figure 15 22 Remove the rear bumper cover from the vehicle and set it aside 23 Remove the two bolts mounting the spare tire winch crank to the passenger
8. 5 Mount the modified bumper on the vehicle using the provided 2 metal spacer tubes between the bumper and the top of the frame Align the bumper mounting holes spacer and frame holes and install a 1 2 x 9 bolt nut and 7 16 USS washer on each side Leave hardware loose Check the clearance between the relocated bumper and frame Make additional adjustments where necessary then torque the 9 16 hardware to 95 ft lbs Loosely install the provided lower bumper brackets on the frame using the holes that were drilled out earlier The brackets are side specific with tabs pointing toward the outside of the vehicle when installed Attach the brackets to the frame with 7 16 x 1 bolts nuts and 3 8 USS washers With the brackets snug against the bottom of the bumper torque hardware to 45 ft lbs Figure 26 Figure 26 Using the slot in the new lower bumper brackets as a template Figure 26 drill a 7 16 hole in the bumper and fasten the brackets to the bumper with 7 16 x 1 bolts nuts and 3 8 USS washers Torque hardware to 45 ft lbs Reattach the inner fender to the bumper with the factory bolts and plastic clips The three lower air vents in the front bumper cover must be trimmed for clear ance in the new relocated position Measure back from the center of the two outer mounting holes 34 and mark Run a cut line across the three vents con necting the two marks At the edge of each vent make a cut line that exte
9. d fasten the 5 back mounts with 12mm x 160mm bolts and 4 SAE washers in conjunction with the factory lower bushings Leave hardware loose The front mount is the same as the others but uses a 12mm x 200mm bolt Lower the body onto the blocks and repeat the procedure on the driver s side While lifting the driver s side pay close attention to the brake lines running to the master cylinder They have ample room to flex but may need reformed by hand to reduce strain on the fittings 32 With both sides lifted go back and remove each bolt one at a time and coat the threads with Loctite Torque all 12 body bolts to 65 ft lbs gt gt UNDER Hoop 33 Install the provided steering extension between the upper and lower sections of the steering shaft that were separated align the marks made earlier Fasten the extension to the lower section of steering shaft with the factory bolt Figure 20 Step 33 Note Fasten the extension to the upper section with a 10mm x 45mm bolt nut and The 10mm steering extension hard 10mm washers Torque 10mm hardware to 30 ft lbs ware is locate in hardware pack 219 Figure 20 34 Reattach the electrical module to the driver s side of the engine with the factory hardware Torque nuts and bolts to 12 ft lbs 35 Locate the negative battery cable wire loom Remove the tape and remove the negative battery cable from the wire loom to gain added length to reach the bat tery Figure 21 Do not hook that
10. n the new bracket and bumper bracket The bolt will run through the new bracket 5 8 spacer washer and into the bumper hole with the welded nut Leave hard ware loose Reinstall bumper with the new brackets attached The mounting holes toward the front of the vehicle will require a 5 8 x 1 1 4 bolt 5 8 SAE washer and provided 5 8 nut tab which goes inside the frame rail All other mounting posi tions require 2 x 1 1 4 bolts nuts and 2 SAE washers Adjust bumper and torque 72 hardware to 60 ft lbs and 5 8 hardware to 115 ft lbs Reinstall rear bumper cover with factory hardware gt gt Spare Tire RELOCATION 62 63 64 65 66 67 Remove mounting hardware from spare tire crank on pass side Do not re move hardware for bracket directly above spare tire Remove nut clip from bracket where it mounts to the rear crossmember Install the provided 2 offset relocation bracket on the passenger s side frame with the factory winch Leave hardware loose at this time Fasten the spare tire winch to the new bracket with a 3 8 x 1 1 4 bolt nut and 5 16 USS washer Leave loose Also loosely attach the other portion of the winch back in its original location on the frame crossmember with the factory hardware Install the provided 2 metal spacer between the rear frame crossmember and winch Figure 34 Attach with 2 x 3 bolt nut and 2 SAE washer Torque 2 bolt to 65 ft lbs
11. nds from the top cut line to the bottom back corner of the vent 6 cut lines total 2 per vent Trim the vents off at the marks Figure 27 51 Install the bumper cover on the vehicle and fasten with the factory plastic clips and hardware Figure 27 gt gt REAR BUMPER 52 Locate the rear most welded nut on each side of the rear bumper Measure for ward from the center of the welded nut 1 and make a vertical cut line Figure 28 Cut the end of the bumper mount off at the line driver s and passenger s side Figure 28 53 Locate the trailer wire bracket Cut the bracket off flush with the bumper using a reciprocating saw or cut off wheel Figure 29 Take care not to cut into the bumper Paint any bare metal on the bumper and bracket to prevent corrosion Step 53 Note Care should be taken in cutting the bracket because it will be reused Try to remove the material at the weld only C9212 Installation pg 15 C9212 Installation pg 16 Figure 29 54 Measure down 1 from the top inside corner of the rear frame rail and mark Measure toward the outside of the frame 1 and mark as well Make cut marks that run back to frame crossmember Cut top and inside of frame rail at marks the end of the cut will align with the cross member that connects the frame rails Figure 30 Paint any bare metal to prevent corrosion Figure 30 55 Place new bumper brackets against inside of frame rails Align the
12. s side frame rail Figure 16 Save bolts Figure 16 24 Remove the bolt mounting the spare tire winch to the frame crossmember and remove the winch and winch crank from the vehicle Figure 17 Save winch mounting bolt Figure 17 25 Remove the three bolts mounting the rear bumper hitch to each of the frame rails and remove the bumper hitch from the vehicle Figure 18 Save hardware C9212 Installation pg 9 Step 30 Note All body mount hardware is located in hardware pack 218 C9212 Installation pg 10 26 At wae i i Ke ty kb hg i 4 bi ry i ARAN x eet Ry gt z S aa in Figure 18 Disconnect the fuel filler tube from the frame by remove the plastic retainer clip and sliding the tab out of the hole in the frame Figure 19 Figure 19 gt gt LIFT Zi 28 29 30 31 Loosen but do not remove all 12 body mount bolts Remove the 6 passenger s side body mount bolts The lower body bushing is captive on the bolt and must be removed for reuse Set the bushing across the jaws of a vise and pound the bolt through with a hammer This will be necessary with all 12 mounts Using two hydraulic jacks and wooden blocks lift the passenger s side of the body just high enough to place the 2 tall body lift blocks between the body and the frame Constantly be checking for any wires hoses etc that may be over extending When the blocks are installe
13. sical shape This includes rusted body mounts damaged or worn frame to body mounting brackets and poor mechanical condition Perform a visual inspection of the vehicle before beginning installation Kit Contents Qty Part 12 2 x 3 Lift Block i Bolt Pack Bolt Pack Bolt Pack Steering Extension Front Bumper Brkt drv Front Bumper Brkt pass 2 Front Bumper Spacer C9212 Installation pg 2 l l 2 l l l 2 4 l l 1 Radiator Brkt drv Radiator Brkt pass Bushing Rear Bumper Brkt drv Rear Bumper Brkt pass 1 2 Bolt Fish Wire 5 8 11 nut tabs 1 2 13 x 1 1 4 bolt tabs 0 750 x 0 095 x 2 000 Spacer Spare Tire Winch Bracket Loctite INSTALLATION INSTRUCTIONS Park the vehicle on a clean flat surface and block the rear wheels for safety l Disconnect the positive and negative battery cables from the battery The 2 Supplemental Restraint System airbags will be deactivated when the battery is disconnected 22 FRONT Remove the front grill by carefully pulling out on it releasing the 11 retaining 3 clips Set grill out of the way 4 Remove the two bolts and one plastic clip from the top center section of the front bumper cover Figure 1 Save bolts and clip Figure 1 Remove the two one per side outer plastic retain clips from the bumper at each 5 wheel well Figure 2 Save clips mq DY ITT b 4 TILL We ib a i fi gt a T La ti Figure 2 6
14. using one of the factory fan shroud bolts Reinstall the plastic core support cover with the original plastic clips gt gt FRONT BUMPER Al C9212 Installation pg 12 Locate the small hole just forward of the BOTTOM mounting holes on the front bumper Make a cut line from the center of the hole on the driver s side of the bumper to the hole on the passenger s side of the bumper Figure 23 This cut will provide clearance for the bumper and the front frame crossmember tube 42 43 A4 Figure 23 Locate the front bumper cut template in the instruction sheet and cut it out Position the cut template on the bottom side of the bumper aligning the hole in the template with the bumper mounting hole Figure 24 Trace the outline of the template on the bumper and repeat on the other side This cut will provide clear ance for the bumper around the frame horns Figure 24 Cut the bumper along the cut lines with a hack saw cutoff wheel or plasma cut ter Paint any bare metal to prevent corrosion Locate the existing holes in the front frame body mount Drill the hole one on each side of the vehicle to 7 16 Figure 25 C9212 Installation pg 13 45 Step 45 47 48 Note All front bumper mounting hardware is located in hardware pack 219 46 47 48 49 Step 49 Note M The inner fender may need to be trimmed slightly to clear the body mount on each side C9212 Installation pg 14 Figure 2
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