low range hd 2 inch body lift kit (sidekick, gv, vitara, tracker, x90)

8/16/2019 Low Range HD 2 Inch Body Lift Kit (Sidekick, GV, Vitara, Tracker, X90)

1/45

Suggested Tools:

• Twin Post Lift (or Floor Jack and (4) SafetyStands)

• Standard Screwdriver

• Phillips Screwdriver• Channel-Lock Pliers

• Sockets: 8,10, 14, 17, 19 mm

• Deep Sockets: 10 mm

• Ratchet

• Socket Extension: 6”

• Wheel Chocks (2)

• Pick Tool

• Ultra-Gray Gasket Maker (Supplied)

CAUTION: Safety glasses should beworn at all times when working withvehicles and related tools andequipment.

Low Range HD 2 Inch Body Lift Kit (Sidekick,

GV, Vitara, Tracker, X90) SKU# KSP-BL2

Installation Instructions

For additional copies of theseand other instructions go to:www.lowrangeoffroad and click on the

“Instructions” tab.

Background: Theseinstructions are designed

for installing the 2” body lift.They can also be usedsuccessfully when installing

the 1” body lift. When doingthese inst ruct ions we

raised the entire body andinstalled all the spacers at

once. However, somehave found success ininstalling the spacers, one

side at a time. This workspart icularly well when

installing the 1” body lift.This could be a better

approach especially if youdo not have a twin post lift.

We recommend readingt h e s e i n s t r u c t i o n sthrough completely,before beginning the

job. This will insure ag r ea te r m a rg in o fsuccess and a morepleasurable experience.

http://www.lowrangeoffroad/http://www.lowrangeoffroad/http://www.lowrangeoffroad/


2/45

Body Bolt andLock

CupWasher

Lower BodyBushing

Upper BodyBushing

NylonWasher

Sleeve

Sleeve

Upper BodyBushing

Lower BodyBushing

Cup Washer

Nut

Frame

F o r w

a r d

Body mount Parts Identification

Figure A

Bolt Type BodyMount (2 Total)

Stud Type BodyMount (6 Total)


3/45

3” Diameter Stud Type Spacers (6 ea.)A

A

A

A

A

A

A

B

B

2” Diameter Spacers W/ No Hole (4 ea.)C

C

C

C

C

Kit Supplied Body SpacerLocations & Sizing

F o r w

a r dFigure B

3” Diameter Bolt Type Spacers (2 ea.)B


4/45

Body

Body Stud

stud type BodyMount Assembly(type “A”)

3” Dia. Bushing(Supplied)

Frame

Existing UpperBody Bushing

Existing LowerBody Bushing

Washer(Supplied)

Stud Extension(Supplied)

Body Lift Kit Component Placement

Figure C

Blue = Supplied PartsRed = Existing Parts


5/45

Body

Frame

3” Dia.

Bushing, W/Hole(Supplied)

Flat Washer(Supplied)

Split Washer(Supplied)

Bolt(Supplied)

Existing BodyBushing

ExistingWelded-On Nut

Bolt type BodyMount Assembly(type “b”)

ExistingBody Pad

Frame

Figure D

Figure E

ExistingNylonWasher

Existing BodyBushing

Existing CupWasher

2” Dia.Bushing, SmallHole(Supplied)

Glue-in type Body

Mount Assembly(type “C”)

Blue = Supplied PartsRed = Existing Parts


6/45

Preparing the Vehicle

Lifting Option 1The preferred method of lifting andsupporting the vehicle is the twin post,frame contact, lift. If this is the methodyou plan to use, position the vehicle asyou normally would, however do not liftit at this time.

A NOTE ABOUT BUMPERSIf the the vehicle you are working withstill has the original FRONT bumper itwill NOT need to be removed. All that isneeded is to remove the grill andheadlights to access the front bodybolts.

If the vehicle you are working with is stillequipped with the original REAR

bumper, it WILL need to be removed inorder to raise the body. However, it canbe reinstalled and attach reasonablywell if you want to reuse it.

Step 1Disconnect the negative battery terminalusing a 10 mm deep socket. This isdone to reduce the risk of cable damageand electrical short circuiting resultingelectrical fires and component damage.

Lifting Option 2If you plan to use another method oflifting and supporting the vehicle, suchas a floor jack and safety stands,position the vehicle on a level floor in aclear work area.


7/45

Tech Tip 2This picture shows the location of thescrew.

Step 2Remove the (1) screw securing the grillusing a phillips screwdriver.

Step 3Remove the driver side of the grill bysqueezing the grill with your right handand pulling forward on the grill with yourleft hand as shown. This will disengagethe snap clips.

Note: Be careful here. The grill and iseasily damaged and the snap clips willmost likely brake. New clips can bepurchased from Suzuki.

Step 4Remove the passenger side of the grillin the same way as the previous step.

Squeeze with the left and and pull withthe right.

Removing the Grill


8/45

Step 5Set the grill in a safe place so it is notbroken.

Note: Placing it on top of the vehicle isa pretty good place.

Tech Tip 6This shows the connector unplugged.

Step 6Insert a small screwdriver as shown andwhile prying slightly, pull the connectortoward the rear of the car.

Removing the Headlight Assemblies


9/45

Step 7Remove the headlight assembly byremoving the (3) bolts using a 10 mmsocket on an extension.

Step 8Lift out the headlight assembly.

Note: Be careful here. There is onemore wire connector that needs to bedisconnected.

Step 10

Repeat Steps 6 through 9 on the driverside headlamp assembly.

Step 9

Disconnect the two wire connector(signal light). This is done by pressingdown on the tab and pulling theconnector halves apart. Then set theheadlight assembly aside in a safeplace.


10/45

Tech Tip 11This shows the parts removed.

Step 11Remove the passenger side front bodymount bolt, split washer, cup washerand upper body bushing using a 14 mmsocket. See Figure A for partsIdentification.

Step 12

Repeat Step 5 on the driver side frontbody mount.

Disconnecting the Front Body Mounts

Step 13Position the lift arms under the frame

according to the illustration above andraise the vehicle up to a comfortableworking hight. If you do not have a liftthese next few steps could be done withthe vehicle on the floor.


11/45

Step 15Remove these (3) screws using aphillips screw driver.

Step 14Remove these (4) screws using aphillips screw driver.

Step 16Remove this passenger side screwusing a phillips screwdriver.

Step 17

Remove this driver side screw using aphillips screwdriver.

Removing the Rear Bumper Cover


12/45

Step 18

Remove these (2) passenger side boltsusing a 10 mm socket.

Step 19

Remove these (2) driver side bolts usinga 10 mm socket.

Step 20Detach the driver side bumper cover byflexing it slightly forward, then outwardunhooking it from the bracket.

Step 21

Remove the bumper by sliding it straightrearward. See the next tech tip beforeperforming this step.


13/45

Forward

Figure F

Rear Body Mount Locations

Unbolting the Rear Body Mounts

Tech Tip 21This is the slide clip that attaches therear bumper cover to the finder on bothsides of the vehicle. To release theseslide clips, slide the bumper coverstraight rearward keeping bumper coverlevel front-to-back and side-to-side.

Start Here


14/45

Step 24Repeat Steps 22 and 23 on thepassenger side body mount.

Step 22Unbolt the driver side rear body mountusing a 14 mm socket. See Figure F for the location of these rear bodymounts.

Step 23Remove the nut, cup washer and lowerbody bushing.

Note: The nut and cup washer can bediscarded. Keep the body bushing. Itwill be needed later. See Figure A forbody parts identification.


15/45

Step 26Set the cover aside.

Step 25Remove the (3) bolts using a 10 mmsocket.

Step 27Remove the (4) fuel neck bolts using an8 mm socket.

Step 28

Remove the fuel cap.

Removing the Fuel Fill Hose Cover


16/45

Step 30Replace the fuel fill cap.

Note: This done mainly to keep dirt fromdropping into the fuel tank.

Step 29Pull the fuel fill hose out of the fender.

Step 32Then remove the nut, cup washer andand bushing.

Note: You can discard the nut and cupwasher but keep the bushing. Thebushing will be needed later.

Step 31Raise the vehicle up and Loosen thebody mount nut located just ahead ofthe PASSENGER REAR tire using a 14mm socket. See Figure G for thelocation of this mount.

Note: This step could be done with thevehicle on the floor or on jack stands.

Unbolting the Lower (4) Body Mounts


17/45

Step 33Repeat Steps 31 and 32 on the other 3 body mounts indicated In Figure G.

Forward

Figure G

Start Here

Step 35Pull the brake junction block away from

the body by gently bending the brakelines.

Note: The brake lines should rest aboutone inch away from the body.

Step 34Disconnect the brake junction block

from the body by removing the (2) boltsusing a 10 mm socket.

Disconnecting the Brake Components


18/45

Step 36Disconnect the driver side front brakeline retainer clip using a standardscrewdriver.

Step 37Free the brake line from the bracket.

Step 39Position the transfer case shifter into the“N” (Neutral) position.

Step 38If raised, lower the vehicle back downnear the floor.

Disconnecting (& Positioning) Other Components


19/45

Step 40

Position the transmission shifter into the“N” (Neutral) position.

Step 41Open the hood and unsnap the wiringrestraint shown here.

Note: This restraint is located on thepassenger side strut tower inside theengine compartment.

Step 42

Slide the coolant reservoir up and out,then lay it aside.

Step 43

Release this zip tie using a standardscrewdriver or a pick tool.

Note: This zip tie is located just aheadof the battery.


20/45

Step 44Release this 2nd zip tie as well.

Step 45Release this zip tie also.

Note: This should allow plenty of slackin the wiring harness. However, acareful inspection of other areas of thewiring harness is advisable. Just tomake sure there are no problems whenthe body is lifted up.

Step 47Disconnect the intake air duct and lay itaside as shown.

Step 46Loosen the intake duct hose clampusing a standard screwdriver.


21/45

Step 48

Disconnect this vacuum switch byremoving the mounting bolt using an 8mm socket.

Note: Do not disconnect any wires orhoses. Simply lay it aside for now.

Step 49Disconnect the O2 Sensor (4 wireconnector) located near the brakemaster cylinder on the driver side of theengine compartment. Simply depressthe tab and separate the two connectorhalves.

Step 51Disconnect this wiring harness restrain

by prying it away from the firewall. Thisis located at the rear of the enginecompartment in the center.

Note: It should simply snap out of thehole.

Step 50Release this zip tie using a standard

screwdriver or a pic tool. This wiringharness is located at the rear of theengine compartment on the passengerside.


22/45

Step 52Be sure the wiring harness has plenty ofslack. If there is not enough slack,unclip any remaining wiring restrains asneeded.

Step 53Disconnect the rear vacuum hose at theevaporative canister as shown.

Step 54Unplug this ground wire located at therear of the engine.


23/45

Step 56Carefully raise the body a little at a time.

CAUTION: Be sure to check all areasof the vehicle where you havedisconnected things as well as all otherareas that could have been accidentallyoverlooked, to insure that no damagewill occur as the body is being lifted.

Step 55Block the passenger side front wheel,

front and rear. Position the lift arms onthe BODY pinch welds as shown.

Note: It may be necessary to place ablock between the rear lift arms and thebody, so the body lifts evenly front-to-rear.

Important: If you place a block on thepassenger side rear, be sure to do thesame to the driver side.

Raising the Body and Installing the Spacers

Step 58If the sleeve did not come off with theupper body bushing, remove the sleevefrom the stud.

Step 57Once the body has been raised about 3inches off the frame, beginning with thebody support that is just ahead of thepassenger side rear wheel, separatethe upper body bushing from the bodyusing a standard screwdriver.


24/45

Step 59Install one of the 3” Dia. spacers on thebody stud.

Note: It may be necessary to raise thebody a little more to make room for thisspacer. If raising the body is needed, besure to check the wires, vacuum hoses,brake lines, etc. to insure that nodamage is occurring while lifting.

CAUTION: DO NOT raise the body anyhigher than is absolutely necessary.

Tech Tip 59

If the stud is rusted, it may be necessaryto clean the stud with a file beforeinstalling the supplied spacer.

Step 61Repeat Steps 57 through 60 on theother (5) body mounts shown in FigureH below.

Step 60Push the supplied 3” Dia. spacer up thestud and install the original upper bodybushing under the supplied spacer asshown.

IMPORTANT NOTICE: Be sure thesleeve has been removed from theoriginal body bushing before installing it.


25/45

Figure H

For ward

Installing the Front (2) Spacers

For ward

Figure I

Start Here

Start Here


26/45

Step 62Begin at the passenger side front body

mount. (See Figure I) If the sleeve isstill in place, remove it.

Notice: Be sure to leave the originalbody mount bushing in place.

Step 63Place a supplied 3” Dia. body spacer ontop of the original body bushing.

Original BodyMountBushing

Step 64Repeat Steps 62 and 63 on the driverside front mount. See Figure I.

Step 65Once all 6 (4 lower and 2 rear) of the 3”Dia. spacers are in place, carefully lowerthe body, a little at a time. Whilelowering the body, observe all (6) of thebody studs. Insure that they are aliningwith the holes in the frame. If the studsare not alining with the holes in theframe, move the frame as needed. Ifthe frame needs to move front-to-back,unblock the wheels and roll it. If the

frame needs to move side-to-side, placea floor jack under the front (or rear) axleassembly and move the frame.

IMPORTANT: Be sure the studs areperfectly centered in the holes beforecontinuing to the next step.


27/45

Step 66Begin at the passenger side rear mountlocation. (See Figure J) Apply some ofthe supplied Ultra-Gray Gasket Maker toone end of a 2” Dia. Spacer.

Note: Apply about 1/16” layer of Ultra-Gray to the entire surface of the spacer.

Step 67

Apply Gasket Maker to the other end ofthe 2” Dia. Spacer the same way it wasdone in the previous step.

Installing the (4) 2” Diameter “Glue-In” Spacers

Forward

Figure J

Start Here


28/45

Step 69Repeat Steps 66 through 68 on theother (3) 2” Dia. Spacers. See Figure Jfor spacer placement.

Step 68Insert the spacer directly below theexisting spacer as shown.

Note: It may be necessary to raise thebody slightly to allow room for thesespacers.

Step 70Once all the 2” Dia. spacers are inplace, lower the body until the body isJUST BEGINNING to rest on the 2” Dia.spacers.

Note: Do not place full body weight onthe spacers yet.

Existing

Spacer


29/45

Step 72Place one of the supplied washers onone of the supplied stud extenders asshown. Then insert the stud extenderinto the lower body bushing.

Step 71Beginning at the mount just ahead of theright rear wheel, separate the cupwasher from the lower body bushing ifnot done previously. See Figure Kbelow for mount locations. Also seeFigure C for hardware and bushingplacement.

Forward

Figure K Start Here

Installing the (6) Stud Type BodyBushings and Stud Extenders.


30/45

Step 74Repeat Steps 71 through 73 at the other5 locations. See Figure K.

Step 73Install the assembled stud extender,washer and bushing through the framebracket as shown. Start the studextender on the stud 3 or 4 turns only.

Note: Do NOT tighten the stud extenderall the way at this point.

Forward

Figure L Start Here

Securing the (2) Front Body Spacers


31/45

Step 76Install the supplied bolt, flat washer andlock washer as shown. Start the bolt 3or 4 turns only.

Note: Do not tighten the bolt all the wayat this Time.

Step 75Beginning on the passenger side,position the original nylon body washer,upper body bushing and cup washer asshown. See Figure D for correct spacerand hardware placement.

Step 77Repeat Steps 75 and 76 on the driverside body mount.

Step 78Lower the body so that the full bodyweight is resting on the spacers.


32/45

Step 82Tighten, then torque all (6) studextenders 16-25 ft. lbs. See Figure K for stud extender locations.

Step 81Reposition the lift arms under the frame

and raise the vehicle to where you cancomfortably work on the under side.

Tightening the (6) Stud Extenders

Step 79Tighten, then torque the diver side frontmount 16-25 ft. lbs.

Step 80Tighten, then torque the passenger sidefront mount 16-25 ft. lbs.


33/45

Step 84The driver side front brake line cannotbe attached to the bracket as it wasbefore. You could build a custombracket or install longer brake lines.Click HERE to see what Low Range hasto offer.

Step 83Reattach the brake line junction blockand torque the bolts to 3-5 ft. lbs.

Step 85Lower the vehicle so you cancomfortably work under the passengerside rear wheel well.

Reattaching Other Body Components

Step 86Loosen the small hose clamp using astandard screwdriver.

http://www.lowrangeoffroad.com/index.php/89-98-sidekick-tracker-x90-extended-front-coated-stainless-steel-braided-brake-lines-0-5-lift-kb-efbl.htmlhttp://www.lowrangeoffroad.com/index.php/89-98-sidekick-tracker-x90-extended-front-coated-stainless-steel-braided-brake-lines-0-5-lift-kb-efbl.htmlhttp://www.lowrangeoffroad.com/index.php/89-98-sidekick-tracker-x90-extended-front-coated-stainless-steel-braided-brake-lines-0-5-lift-kb-efbl.html


34/45

Step 87Using a pair of cannel lock pliers, lightlygrip the hose, twist and slide it downabout 1/2”.

Caution: Do not damage the hose.

Step 88Repeat Steps 86 through 87 on thelarge hose.

Tech Tip 88If you find the larger hose difficult to

break loose and slide down, you maywant to try reconnecting the fuel tank fillneck to the body with the (4) screws(See Steps 89 through 91) and thenslide the hose down the pipe.

Step 89Remove the fuel cap.


35/45

Step 91Snug the bolts. Do not over-tighten.These are easily stripped.

Step 90Position the fuel fill nozzle back in thebody and install the (4) bolts.

Step 92Adjust both hoses as close to theiroriginal position as you can withoutcausing the hoses to kink or rub.

Step 93Reinstall and tighten both hose clamps.


36/45

Step 95Reposition the air intake duct and snugthe hose clamp.

Caution: Do not over tighten this hoseclamp.

Tech Tip 95

It may be necessary to disconnect theupper air cleaner assembly, reattach theduct, then reinstall the upper air cleanerassembly. Use an 8 mm socket toremove the (4) bolts.

Reattaching the Under-Hood Components

Step 94

Reinstall the fuel fill cap.


37/45

Step 97Reconnect this ground wire located onthe rear of the engine.

Step 96Reconnect O2 Sensor wire.

Step 98Reconnect this wiring harness restraintin both places.

Step 99

Reattach this vacuum switch.


38/45

Step 100Reconnect these (2) wire restraints.

Tech Tip 99Do not over-tighten this bolt. Just snugis enough.

Step 101Reinstall the coolant recovery bottle.

Step 102

Reconnect the evaporative canister rearhose.


39/45

Step 104Reposition the headlight assembly in itsoriginal location

Note: Be sure the headlight adjustersare positioned properly.

Step 105Install the (3) bolts and snug themdown.

Installing the Headlights, Grill and Front Bumper

Step 103Hold the driver side headlight assemblyclose to its original location and plug inthe two wire connector as shown.

HeadlightAdjuster

Step 106Reconnect the headlamp electricalconnector. Push it into place until itsnaps.


40/45

Step 107Repeat Steps 104 through 106 on thepassenger side headlamp assembly.

Step 108Reposition the grill and snap it intoplace.

Step 109

Reinstall the (1) screw as shown.


41/45

Step 110Position the rear bumper as shown

Note: The slide clips will not engageafter the body has been lifted.

Step 115Reinstall the bumper cover upperscrews but leave them loose for now.

Installing the Rear Bumper

Notice: The rear bumper cover attaches to the frame and the body. Since the body isnow 2” higher that it was originally the bumper will not fit exactly as it did. However, witha bit of flexing, the bumper will fit and look reasonably good. Of course you could alsouse a custom bumper it its place if you wish. Click HERE to see rear bumpers availablethrough Low Range Off-Road.

Step 117Flex the driver side bumper cover overthe bracket and install the screw. Leavethe screw loose for now.

Step 116Flex the passenger side of the bumpercover over the bracket as shown.

http://www.lowrangeoffroad.com/index.php/catalogsearch/result/?q=sidekick+rear+bumperhttp://www.lowrangeoffroad.com/index.php/catalogsearch/result/?q=sidekick+rear+bumperhttp://www.lowrangeoffroad.com/index.php/catalogsearch/result/?q=sidekick+rear+bumperhttp://www.lowrangeoffroad.com/index.php/catalogsearch/result/?q=sidekick+rear+bumper


42/45

Step 118Install the (3) lower-center bumper coverscrews and leave them loose for now.

Step 119

Install the passenger side lower screwsand leave them loose as well.

Step 121

Now that all the bumper cover screwsscrews are in place and started, tightenthem using a phillips screwdriver and 10mm socket.

Step 120

Repeat previous step on the driver sidelower bumper cover screws.


43/45

Step 122Reinstall the fuel fill hose cover. One ofthe 3 screws will not be installed. Youcould build custom bracket or simplyleave it out as we did. It is up to you.We feel the cover is secure enough withonly two screws.

Step 123Lower the vehicle to the floor.

Step 125Sit in the driver seat, push down on theclutch, start the engine and check to see

that the transfer case and transmissionshifters move all the way into each gear.We did not have any trouble with ourinstallation. However, if you do, it maybe necessary to remove the shifterboots and enlarge the shifter openingsin the body.

Step 124Reconnect and tighten the negativebattery cable.


44/45

Congratulations:You have successfully completed aSidekick body lift. We hope theseinstructions have been helpful. Ifyou have suggestions on how we

can improve these instructions orou r pr od uc ts , em ai l us a [email protected] or callus at 801-805-6644.

mailto:[email protected]:[email protected]:[email protected]


45/45

As always, If you experience any difficulty during the installation of this productplease contact Low Range Off-Road Technical Support at 801-805-6644 M-F7:30am-5:30pm MST. Thank you for purchasing from Low Range Off-Road.

These instructions are designed as a general installation guide. Installation of many Low RangeOff-Road products require specialized skills such as metal fabrication, welding and mechanicaltrouble shooting. If you have any questions or are unsure about how to proceed, please contactour shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools suchas welders, torches and grinders can cause serious bodily harm and death. Please operateequipment carefully and observe proper safety procedures.

Rock crawling and off-road driving are inherently dangerous activities. Some modifications willadversely affect the on-road handling characteristics of your vehicle. All products sold by LowRange Off-Road are sold for off road use only. Any other use or application is the responsibilityof the purchaser and/or user. Some modifications and installation of certain aftermarket parts may

under certain circumstances void your original dealer warranty. Modification of your vehicle maycreate dangerous conditions, which could cause roll-overs resulting in serious bodily injury ordeath. Buyers and users of these products hereby expressly assume all risks associated with anysuch modifications and use.

Revised 12/03/13© Copyright 2013 Low Range Off-Road, LC All Rights Reserved

low range hd 2 inch body lift kit (sidekick, gv, vitara, tracker, x90)

Documents