Chevrolet 170 Automobile User Manual
Contents
1. PHOTO 13 50061011 Chevy Impala A Division of KW automo PHOTO 14 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 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 PHOTO 15 50061011 Chevy Impala A Division of KW automoti 3 STEP 7 MOUNTING THE DOOR TO THE A FRAME IMPORTANT NOTE THIS STEP SHOULD BE DONE WITHOUT THE GAS SPRING INSTALLED 7 Place the door back on the vehicle and close the door completely 7 Install the MAGICSTIK into position Photo 16 Initially this is done for mounting pur poses 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 7 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 horizon tal door gap2. CHEVY IMPALA 1992 1996 LSD INSTALLATION 50061011 Chevy Impala SS A Division of KW automotive North America Inc h 50061011 Chevy Impala S A Division of KW automoti EJ 50061011 Chevy Impala SS 2 En A Division of KW automotive North America Inc Y a fey 3 Ji 1 A gt por F Letti o linet PERSE oa INSTALLATION INTRODUCTION REMOVING THE FENDER DOORS FROM THE A PILLAR AND DISCONNECTING THE WIRE HARNESS THE DOOR JAM REMOVING THE EXISTING DOOR HINGES FROM THE DOORS TOP AND BOTTOM MODIFYING THE INTERNAL FENDER AREAS FOR THE HINGE CLEARANCE MODIFYING THE ELECTRICAL HARNESS INSTALLING THE GROUND PLATE TO THE A PILLAR AND THE SWING ARM TO THE DOOR HANGING AND ALIGNING THE VEHICLE DOORS INSTALLING THE FENDER AND CHECKING FOR CLEARANCE REMOVE FENDER AND ROUTE THE WIRING RE INSTALL FENDER AND CHECK FOR CLEARANCE JOB COMPLETE T m T Fi shia Installation Instructions LamboStyleDoors The instructions are to be used as a reference only Please repeat steps for both doors Pre installation check list eBattery disconnected Front bumper removal Front fender removal eVehicle 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 t
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4. Impala SS b k i a A Division of KW automotive North America Inc h Es 10 m es 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 1 Lo Xs I 1 1 able STEP 1 INNER FENDER MODIFICATION cont d 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 outlined in white that will need to be removed 1 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 PHOTO 1 PHOTO 2 PHOTO 3 50061011 Chevy Impala SS i m EE 1 A Division of KW automotive North America Inc ni zi pi ass T Mei TM at STEP 1 INNER FENDER MODIFICATION cont d 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 outlined in white that will need to be removed 1 The secondary cut for the removal of the l
5. be aware your car might have different factory installed equipment from our tested R amp D vehi cle in this case please contact your LSD dealer to order higher or lower power gas damper units an addi tional 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 Isd 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 work ing 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 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
6. 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 f 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 A Division of KW automoti E HARDWARE LIST per vehicle side 0 LSD Warning notice Shim Roller Mount 50061011 Chevy Impala ma A Division of KW automoti 50061011 Chevy Impala SS a A Division of KW automotive North America Inc EE ab Eric 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
7. 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 specifica tions 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 soeaker 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
8. the snap rings are installed cor rectly and are snapped their respective guides 50061011 Chevy Impala SS A Division of KW automotive Y 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 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 prop erly 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 ad justment 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 spe cific 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
9. 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 lt i d Fk 1 33 2 4 si A bot att ut p c ts r ee E a e Tuo x AIF e EPA a agb proto p Vox Viam UT ai o a TUE n TA LU Le war EF deal ok 8 STEP 2A STEP 1B TOP STEP 2B BOTTOM PHOTO 21 install gas spring and check door alignment again Repeat if necessary 50061011 Chevy Impala A Division of KW automo STEP 10 ROUTING THE WIRE HARNESS 10a Pivot the door carefully up and make sure there is sufficient clearance on the fender A pillar 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 Exact locations for clips may vary for the amount of wiring on vehicle PHOTO 26 50061011 Chevy Impala S i A Division of KW automoti 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
10. 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 1 Oft Ib PHOTO 17 INITIAL ADJUSTMENT OF THE DOOR 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 Te Adjustment depth of the door is by moving the door horizontal Make sure the mount ing hardware is loosened to be able to do this 50061011 Chevy Impala A Division of KW automoti 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 PRE VENT 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 Sus 3 A Division of KW automoti wel 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 loc
11. arge 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 ex posed 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 Te This portion of the inner fender modification is complete 50061011 Chevy Impala hk A Division of KW automoti m STEP 2 INNER FENDER MODIFICATION cont d For this particular application also the outer fender also needs to be modified to accom modate 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 23 5cm PHOTO 6 50061011 Chevy Impala Im A Division of KW automoti 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 PHOTO 8 PHOTO FOR REFERENCE ONLY STEP 4 MOUNTING THE GROUND PLATE TO THE A PILLAR 4a Using the kit supplied m
12. ated on top of the gas damper has to be moved Photo 23 be tween the Ground plate and the top of the ball joint of the gas damper Photo 24 PHOTO 2 2 PHOTO 23 8d 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 25 PHOTO 24 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 TAN e A Division of KW automoti rh STEP 9 FINAL DOOR ADJUSTMENT IF REQUIRED 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 in stances 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 S i A Division of KW automoti j 7 F ETH PETI MEER c sees Lj M im IF
13. e door will move the door in In some cases the mounting will be slightly different be tween top and bottom mounts WHY DO THE DOORS SPRING A JAR WHEN OPENING THE DOOR 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 misalign ment 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 ve hicle 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 WHY DOES THE DOOR HITS RUBS AGAINST THE FENDER WHEN OPENING 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 WHY IS THE WIRING HARNESS TOO LARGE FOR THE ROUTE SHOWN IN THE INSTRUC TIONS LSD door hinges are engineered and designed to compensate for this issue LSD wiring kits are de signed for the MAXIMUM wires installed on vehicles If additional wires are added or modified
14. he 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 ma A Division of KW automoti DANGER WARNINGS LSD Doors must be installed according to the provided vehicle specific instructions from LSD Doors and in stallation 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 sys tems check with the specifications of the vehicle manufacturer When modifying vehicles equipped with
15. hoto 10 Twist the end tight Cut the wire sheath insulation from kit supplied white wire back approximately 1 4 Twist the end tight Using the kit supplied heat shrink connector ends insert the wire ends into the connec tor one from each end Photo 11 Using the heat gun shrink wrap the connector ends to securely mate with the wire ends Photo 12 10 PHOTO 11 PHOTO 12 STEP 5 MODIFYING THE CHASSIS WIRING HARNESS cont d 5g 5h 5i 5j 5k 5m VERY IMPORTANT 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 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 har ness Wire harness flexibility would be minimal 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 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 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 CORRECT CUTS
16. initial contact and pre load 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 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 PHOTO 28 SLIDE ROLLER MOUNT PHOTO 28a 50061011 Chevy Impala A Division of KW automoti 3 1 A1 Q2 A2 Q3 A3 Q4 A4 Q5 5 50061011 Chevy Impala SS A Division of KW automotive North Ame COMMON TROUBLESHOOTING QUESTIONS and ANSWERS WHY DOES THE BOTTOM OF THE DOOR NOT SIT FLUSH AT THE FRONT OR REAR 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 to wards the interior of the door top or bottom will move the door out mounting the swing arm towards the exterior of th
17. ounting 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 TOP MOUNT 4b 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 us ing existing hardware anchoring the top of the Ground plate to the top of the A Pillar Ja LUN ECL 50061011 Chevy Impala SS nre A Division of KW automotive North America Inc lieet el LN STEP 5 MOD IFYING THE CHASSIS WIRING HARNESS IMPORTANT NOTE Prior to beginning extending the wiring harness from the A pillar each See wires individual wire needs to be cut one at a time Each wire that is cut has to be staggered 5g from the previous cut wire By doing this you will eliminate when wrapping all the one large taped ball 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 5 od 5e of PHOTO 50061011 Chevy Impala A Division of KW automo Isolate a single wire Photo 9 Start the first cut on the white wire approximately 3 from the door frame Cut the wire sheath insulation coming from door frame back approximately 1 4 P
18. that are larger than original wiring routing might have to be modified Vehicle owners are responsible for this modified routing WHY DOESN T THE GAS SPRING HOLD THE DOOR UP 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 de creases 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 re placement s 15 Door opening chart for 24 and 30 degree bearing assemblies Depending on how the angle adjustment screw is set on the bearing assembly dimensions can vary up to 2 inches To convert from millimeters to inches divide mm by 25 4 andinchesto millimeters multiply by 25 4 Door Length m z TA Barn Opening Angle Ezarirg sam 50061011 Chevy Impala A Division of KW automoti e x o e usu zd des ele eoo e seis T alele a METRIC TO INCH CONVERSION TABLE 0 21 ALE m LT Jj EL 0 4 0 016 0 8 0 032 20 0 787 60 2 362 100 3 937 0 01
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