Kia - Spectra - Workshop Manual - (2002)

BX2703 Installation Instructions 1998-01 KIA Sephia 2002 KIA Spectra Utilization of Blue Ox baseplates with any tow bar not approved by Automatic Equipment Mfg. Co. invalidates the limited warranty. The head lights and lower plastic bumper need to be removed. Four 3/8 inch holes need to be drilled into the tie down brackets. 1. Remove the headlights by removing the two bolts from each head light assembly (10mm bolt). Remove the 10mm nut holding the front bumper covering to the front quarter panel. Once the headlight is out, remove the plastic push pins inboard of each headlight that hold the bumper covering to the bumper (phillips screw driver). 2. Remove the 4 plastic push pins (phillips screw driver) holding the bumper cover to the upper radiator support frame. 3. Pull the black plastic fender well plastic in front of the tires to reveal the phillips head screw and remove this screw (both sides). 4. Remove the three plastic push pins in the grill opening holding, the bumper molding to the inner bumper. Also remove the four plastic push pins (phillips screw driver) underneath, holding the bumper molding to the brackets bolted to the lower radiator support. 5. Remove the two plastic push pins which are underneath holding the bumper molding on in front of the tires, pull the bumper off. 6. Line up the two holes in the bottom braces of the baseplate (Item 1) with the two existing holes in the front of the radiator support. Start the 1-3/8 bolts with flat and lock washers (Items 8,9 and 10) in from the front and feed the 3/8 wire nut plate (Item 7) in from the two large holes (1 inch diameter) in the rear of the radiator support. 7. Loosely bolt the Rear Braces (Items 3 and 4 for Sephia or items 5 and 6 for the Spectra) and the spacers (Item 2) to the baseplate (Item 1). Hold the Rear Braces (Items 3 and 4 or 5 and 6) against the tie down brackets and drill the two 13/32 inch holes on each side into the tie down brackets. 8. Bolt the Rear Braces (Items 3 and 4 or 5 and 6) to the tie down brackets. The top bolts and washers (Items 8 and 9) will use the 3/8 wire nut plate (Item 7) through the large hole in the front of the radiator support. The bottom bolts and lock washers use the 3/8 Hex nut (Items 8, 9 and 11). 9. Tighten all bolts in the tie down brackets first then the ones connecting the rear braces through the spacers to the baseplate. Apply Loctite to the bolts and tighten. Torque each bolt according to the torque guide included in the General Instruction Sheet. 10. 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 for easy installation, it may be necessary to file a hole slightly. 11. Replace the bumper molding and head light assemblies. 12. DEALER OR INSTALLER: BE CERTAIN THE USER RECEIVES THE INSTRUCTION SHEET. Page Automatic Equipment Mfg. Co. One Mill Road, Industrial Park  Pender, Nebraska 68047 1 of 2 292-2418 Rev. B 12/10/10 9/16 Wrench/ Socket 1/2" Drill Bit Ref No 1 2 3 4 5 6 7 8 9 10 11 Qty 1 2 1 1 1 1 4 10 10 6 6 2 4 Tools Required Phillips Screwdriver Flat Head Screw Driver Loctite Blue Parts List Part No Description 61-5250..........................................................................................Weldment, BX2703 102-5573........................................................................................................... Spacer 102-5569.........................................................................Rear Brace, Passenger Side 102-5574................................................................................ Rear Brace, Driver Side 61-5791....................................................................... Weldment, Brace, DS, BX2703 61-5792....................................................................... Weldment, Brace, PS, BX2703 61-5793...................................................................... 3/8-16, Nut Plate, with 10" Wire 201-0440............................................................... 3/8-16 x 1 1/2 Hex Bolt, Grd. 5, ZP 203-0010..................................................................................... 3/8 Lock Washer, ZP 203-0003.......................................................................................3/8 Flat Washer, ZP 202-0003.......................................................................................3/8-16, Hex Nut, ZP 226-0046........................................... Baseplate Safety Cable, 36" CL III (Not Shown) 229-0359..................................................................... Quicklink, 3/8, ZP (Not Shown) Page 2 of 2 292-2418 Rev. B 12/10/10 © 1998, 2010 Automatic Equipment Mfg. Co. Pender, NE 68047 General Information 1. Ensure that your product(s) are registered online at www.blueox.com. It is crucial to register your product(s) so that you may be alerted of product offerings, updates, upgrades, maintenance and safety bulletins, and/ or recalls. 2. It is the owner’s responsibility to inspect all towing equipment for cracked welds, missing or worn parts and loose bolts before each towing trip. Be sure to use Loctite® Red on all bolts and tighten to the recommended specifications. 3. It is the owner’s responsibility to hook up all towing equipment per manufacturer’s instructions/ recommendations. 4. Remove the attachment tabs when not in use (if applicable). Notice To Baseplate Installer 1. It is YOUR responsibility to watch for: • Oil cooler and air conditioner lines • Electrical wires and hoses • Missing parts or attaching points on the frame ** If the baseplate is improperly installed and is against a wire or hose, it could cause fluid leaks or electrical shorts some time after the actual baseplate installation. Permanent Baseplate Safety Cable Installation Permanent baseplate safety cables are strongly recommended when towing a vehicle with a tow bar. The principle function of the permanent baseplate safety cables is to prevent the towed vehicle from breaking loose in the event the connection between the frame of the towed vehicle and the baseplate fails or becomes disconnected. The cables must be connected from the baseplate to the frame rail or cross member of the vehicle’s frame. The illustrations below show the possible arrangements recommended by Blue Ox®. Each permanent baseplate safety cable must have an adequate weight rating for the towing system. The weight rating of the two (2) cables together will not qualify. Do not mount the permanent baseplate safety cables against wires, hoses or brake lines. These permanent baseplate safety cables should remain installed as long as the baseplate is installed on the vehicle. Permanent baseplate safety cables are to be used in conjunction with, and NOT a replacement for legally required safety cables attaching the towed vehicle to the towing vehicle. 5/11/15