Chevrolet - Lumina - Owners Manual - 1990 - 1993

BX1610 Installation Instructions 1990-93 Chevrolet Lumina APV 1990-92 Oldsmobile Silhouette 1990-93 Pontiac Trans Sport Installation of this baseplate requires removing the headlight assemblies and drilling holes in the frame. 1. Read the General Instruction Sheet included with this baseplate. 2. The baseplate mounts to the front underside of the vehicle using 10 bolts; 3 at each bumper shock unit, and 2 at the front of each side of the engine/transaxle subframe. 3. Open the hood and remove the headlight assemblies and a small rectangular plastic part at the upper center of the grill in order to allow access to the 3 bolts on each side that attach the bumper shock absorbers to the chassis. The headlight assemblies are easily removed by hand by unscrewing 2 large plastic headed bolts from each side. Next, lift the units up and out. Disconnect the plugs to allow complete removal. Remove the 2 bolts holding the small plastic grill part with a 10mm socket. 4. Look down at each bumper shock unit and note the plastic barrier on each side. Pop 3 plastic push rivets on each side and move the barriers back and away to allow free space from the center of the vehicle to the bumper shock absorbers. 5. Remove the 3 bolts that attach the bumper shock absorbers to the chassis with a 13mm socket, one side at a time. Position the appropriate upper bracket to align with the holes. Apply Locktite and add a lock washer to the 8mm x 30mm bolts that are provided. Reassemble loosely. 6. Position the cross tube assembly so that the bolt tabs align to the 2 holes at the lower end of the upper brackets. The upper brackets are positioned on the outside, the tabs are on the inside. Using the 1/2-13 hardware that is provided, loosely attach each side with a pair of bolts, lock washers, and nuts. Use Locktite. 7. The lower arms attach the cross tube to the vehicle's subframe. Loosely bolt the lower arms to the cross tube assembly using 1/2-13 bolts, lock washers, and flat washers. Note that the nuts are already welded to the cross tube assembly. The flange on the lower arms should be to the inside and down. 8. Place a lockdown plate with disc between each lower arm and the subframe so that the disc fits into the approximately 3" diameter hole in the subframe. The small hole in the disc center aligns with the rear hole in the lower arm. The other hole in the lockdown plate should be facing forward and approximately centered on the subframe. There is no matching subframe hole. Place the lockdown plate on the upper side (inside) of the subframe with the holes aligned to those on the mount bars. 9. Hand tighten a 1/2-13 bolt, lock washer, and nut through each lower arm, lockdown plate with disc, subframe and lockdown plate. Be certain the disc is aligned to the large hole in the subframe. Automatic Equipment Mfg. Co. One Mill Road, Industrial Park l Pender, Nebraska 68047 292-1042 8/98 1 of 3 10. Tighten the upper brackets to the chassis with a 13mm socket 11. Tighten the cross tube to the upper brackets with a 3/4" socket and open end wrench. 12. Hand tighten the lower arms to the cross tube. 13. Align the unused holes on the lower arms and the lockdown plates with discs. By using a 17/32" transfer punch, center punch the frame and drill to 17/32" diameter. 14. Place a 1/2-13" bolt through the holes just drilled to attach the lower arms, lockdown plate with disc, subframe, and lockdown plate. Place a lock washer and nut, and fully tighten, both this bolt and the adjacent bolts that also goes through the subframe using 3/4" tools. 15. Tighten the bolts attaching the lower arms to the cross tube using 3/4" tools. 16. Notch and reposition the plastic barriers that were previously removed in step 4. 17. Replace the headlights and plastic center part which was removed in step 3. 18. The dimensional variations between otherwise identical cars can be considerable. While the location and size of the holes in the baseplate were designed to allow easy installation, it may be necessary to file a hole slightly to allow a bolt to clear. 19. Install the tow bar and safety cables according to the instructions included in their packages. 20. Do not substitute other devices if the tow bar pin and clip are lost. 21. DEALERS AND INSTALLERS: BE CERTAIN THE USER RECEIVES THE INSTRUCTION SHEET. Tools Required 3/4 socket 13mm socket 17/32 drill bit 17/32 transfer punch 292-1042 8/98 2 of 3 10mm socket 3/4 open end wrench Drill Loctite Ref. No. Qty. 1 1 2 1 3 1 4 2 5 1 6 1 7 2 8 12 9 6 10 8 11 4 12 12 13 6 Part No. Parts List Description 61-3594 .............................................................................................................. Main Baseplate Assembly 61-3595 .......................................................................................................... Driver's Side Upper Bracket 61-3596 ............................................................................................... Passenger's Side Upper Bracket 61-3599 .................................................................................................................... Lockdown Plate w/Disc 102-3111 ................................................................................. Passenger's Side Support Connector 102-3112 ............................................................................................ Driver's Side Support Connector 102-3115 .................................................................................................................................. Lockdown Plate 201-0051 .................................................................................................................. 1/2-13 x 1 1/2 Hex Bolt 201-0446 ....................................................................................................... 8mm-1.25 x 30mm Hex Bolt 202-0005 .................................................................................................................................... 1/2-13 Hex Nut 203-0005 .................................................................................................................................. 1/2 Flat Washer 203-0012 ................................................................................................................................ 1/2 Lock Washer 203-0102 ............................................................................................................................8mm Lock Washer 292-1042 8/98 3 of 3 © 1995 Automatic Equipment Mfg. Co. Pender, NE 68047