Service Procedure

1. Remove the two 3/8-inch diameter flange bolts and locknuts securing the lower cross tube of the brush/grille guard to the vehicle bumper and remove the license plate bracket. Discard the two 3/8-inch diameter flange bolts and locknuts.

2. Loosen the two 1/2-inch diameter flange bolts securing the brush/grille guard side plates to the vehicle frame and carefully lower the brush/grille guard to the ground.

IMPORTANT!
The 1/2-inch diameter flange bolts must be loosened to enable the slotted holes in the lower cross tube tabs to correctly align with the mounting holes in the bumper during installation of the reinforcement kit.







3. Place the license plate bracket in front of the reinforcement plate so that the mounting holes on the plate and bracket line up (Figure 1).

4. Raise the brush/grille guard up so that the slotted holes in the lower cross tube tabs are close to the mounting holes in the bumper.

5. While holding the license plate bracket and reinforcement plate together, line up the mounting holes in the bracket and plate with the slotted hole in one of the lower cross tube tabs (Figure 1).

6. Insert one of the new 3/8-inch diameter flange bolts into the slotted hole and through the mounting holes in the bracket and plate.




























IMPORTANT!
The 3/8-inch diameter flange bolts supplied in the reinforcement kit are pretreated with thread adhesive (ND Epoxy-Lock(R) Orange U.V. PCH). No extra thread treatment is required for their installation. Refer to the Material Safety Data Sheets, included in this Campaign Bulletin, to ensure safe and proper handling of the thread adhesive.

7. While holding the 3/8-inch diameter flange bolt against the slotted hole, insert the 3/8-inch diameter flange bolt into the mounting hole in the bumper. Shift the brush/grille guard as necessary, to ensure proper bolt-to-mounting hole alignment.

8. While holding the brush/grille guard flush against the bumper, position the rear reinforcement plate behind the bumper. Line up the captive nut on the plate with the protruding 3/8-inch diameter flange bolt in the bumper, and thread the bolt into the captive nut, hand tight, to anchor the brush/grille guard to the bumper (Figure 1).

9. Grip the loose end of the front reinforcement plate and license plate bracket together and align their mounting holes with the slotted hole in the remaining lower cross tube tab. Insert the remaining 3/8-inch diameter flange bolt into the slotted hole, through the plate and bracket mounting holes, and into the remaining mounting hole in the bumper (Figure 1).

10. Reach behind the bumper and grasp the loose end of the rear reinforcement plate. Line up the remaining captive nut on the plate with the protruding 3/8-inch diameter flange bolt, and thread the bolt into the captive nut, hand tight (Figure 1).

11. Remove and discard the 1/2-inch diameter locknut from the 1/2-inch diameter flange bolt securing the brush/grille guard side plate to the vehicle frame. From the reinforcement kit, apply thread adhesive (ND Epoxy-Lock(R) Orange U.V. Resin) to the threads and install a new 1/2-inch diameter locknut, hand-tight. Repeat for the remaining 1/2-inch diameter nutlock and bolt.

IMPORTANT!
Refer to the Material Safety Data Sheets, included in this Campaign Bulletin, to ensure safe and proper handling of the thread adhesive.

12. Torque each 1/2-inch diameter flange bolt to 75.ft. lbs. Torque each 3/8-inch diameter flange bolt to 30 ft. lbs.





13. Affix a campaign label (Part No. 2-90028-700-0) adjacent to the manufacturer's identification label located on the driver's side B-pillar. Using a ball-point pen, fill in the label with Campaign Number 96S-001, Isuzu dealer code, and repair date (Figure 2).