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BODY AND TRIM
HEAVY DUTY BUMPER INSTALLATION
1.
Position brush guard mounting bracket (4) onto brush guard weldment (5). Align holes and secure with four
screws (1), eight washers (3), and four locknuts (2) (Figure 4-1, Page 4-4)
2.
Attach plastic bumper (13).
3.
Use the existing fastener holes in the mounting bracket and vehicle structure as an alignment guide.
4.
Secure the brush guard mounting bracket to the vehicle using two screws (1), four washers (3), and locknuts (2).
5.
Tighten all attaching hardware to 15 ft·lb (20.3 N·m).
6.
Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
See Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.
COWL REMOVAL
1.
Park vehicle and chock tires.
2.
Disconnect the batteries. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
See Disconnecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.
3.
The cowl is secured by tabs located behind the front fenders (2), and under the lip of the dash (1) (Figure 4-2,
Page 4-6).
4.
Push down and rearward on front fenders to unsnap cowl in two locations.
5.
Slide cowl forward until free, then lift out cowl.
COWL INSTALLATION
1.
Slide bottom edges of cowl into grooves in front fenders.
2.
Ensure the three tabs on cowl install under lip of dash (1) (Figure 4-2, Page 4-6).
3.
Ensure sides of cowl (3) assemble between the two ribs on side of dash.
4.
Ensure center tab on cowl assembles beneath the rib in the grille.
5.
With fenders disengaged from the front bumper, press down on front fenders, line up cowl tabs and fully engage
snap tabs.
6.
Ensure front corners of cowl are engaged with front fender (2).
7.
Engage the front fenders to the body clips under the front bumper.
NOTE: Ensure that cowl is fully engaged to prevent dislodging during use.
8.
Connect the batteries. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4. See
Connecting the Battery – Gasoline Vehicles, Section 1, Page 1-4.
9.
Remove tire chocks.
2015 Carryall 500 and 700 Maintenance and Service Manual
4
Front Body
Page 4-5
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Table of Contents
Troubleshooting
