TEL -866-XANATOS INSTALLATION INSTRUCTIONS PART#: 7D5000SS\7D500A GRILL GUARD FOR DODGE SPRINTER 07-09
PARTS LIST: 8 6 Grille Guard Driver/Left Frame Mounting Passenger/Right Frame Mounting Driver/Left Bottom Support Passenger/Right Bottom Support Driver/Left Top Support Passenger/Right Top Support 3/4 OD x 3/8 Tall Tube Spacers (Bottom Support) -.75mm x 35mm Bolt Plate with mm Nut 8-.5mm x 5mm Bolt Plate (5mm x 3mm plate) -.75mm x 35mm Hex Head Bolts mm x 3mm OD x 3mm Flat Washers Passenger side Bottom Support Passenger Side Frame 0 8 4 4 mm Lock Washers mm Hex Nuts 0-.50mm x 5mm Button Head Bolts 0mm x 0mm OD x mm Flat Washers 0mm Nylon Lock Nuts 8-.5mm x 0mm Button Head Bolts 8-.5mm x 40mm Hex Head Bolts 8mm Lock Washers 8mm x 6mm OD x.6mm Flat Washers 8mm x 4mm OD x mm Flat Washers 8mm Hex Nuts 8mm Nylon Lock Nuts Passenger side Top Driver side Top Support Support (Note notch) (Note notch) () Tube Spacers () mm Bolt Plates w/ Nut Driver side Bottom Support Driver Side Frame 8mm x 5mm Bolt Plates PROCEDURE:. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. OPTIONAL DRILLING.. Starting on the driver side of the vehicle, locate the factory hole in the bottom of the frame rail, (Figure ). Insert one of the mm Bolt and Nut Plates into the frame rail, (Figure ). NOTE: Insert Bolt Plate with welded nut facing the front of the vehicle. The notch cut into the Bolt and Nut Plate is designed to clear hardware attached to the frame. It is important to correctly orient the Bolt and Nut Plate. 3. Partially hang the driver side Frame Mounting from the Bolt and Nut Plate using the included () mm Lock Washer, () mm Flat Washer and () mm Hex Nut, (Figure 3). NOTE: Repeat steps & 3 for passenger side Frame Mounting installation. 4. Next, remove the two torx bolts located in the bottom of the front bumper air intake, (Figure 4). Place a Tube Spacer into each of the recessed mounting locations, (Figure 5). 5. Position the Bottom Support s over the Tube Spacers. Use the included () 8mm x 40mm Hex Head Bolts, () 8mm x 4mm Flat Washers and () 8mm Lock Washers to Page of 5
attach the Bottom Support s to the front bumper, (Figure 6). Do not tighten hardware at this time. 6. Open the hood and locate the factory hole on each side of the radiator support, (Figure 7). Remove the screw securing the grille to the radiator support. Place the driver side Top Support up to the factory hole and reinstall the screw through the bottom oval slot in the Top Support. Leave loose at this time. 7. Insert one of the 8mm Bolt Plates into the factory hole through the back of the radiator support, (Figure 8). Insert -3 8mm x 6mm Flat Washers as a spacer between the radiator support and the Top Support. NOTE: It may be necessary to gently push down on the top of the plastic grille to provide clearance for the flat washers/spacers. Secure the Top Support to the Bolt Plate using () 8mm x 6mm Flat Washer, () 8mm Lock Washer and () 8mm Hex Nut, (Figure 9). Repeat Steps 6-7 to install the passenger side Top Support. 8. With assistance, position the Grille Guard face down on a clean surface in front of the vehicle. Move the mountings tabs on the Grill Guard up to the outside of the Frame Mounting s. Line up the rear-most holes in the Mounting s with the Grille Guard. Insert () mm x 35mm Hex Head Bolt, () mm Lock Washer, () mm Flat Washers, and () mm Hex Nut into each of the rear mounting holes to act as a hinge and rotate the Grille Guard up into position, (Figure 0). Install the mm hardware into the remaining (4) mounting locations. Do not tighten hardware at this time. 9. Partially attach the Grille Guard to the Bottom Support using the included () 0mm x 5mm Button Head Bolts, (4) 0mm Flat Washers and () 0mm Nylon Lock Nuts, (Figure ). Proceed to attach the Grille Guard to the Top Support s using the included () 8mm x 0mm Button Head Bolts, (4) 8mm x 6mm Flat Washers and () 8mm Nylon Lock Nuts, (Figure ). 0. Align Grille Guard properly and tighten all hardware at this time.. Do periodic inspections to the installation to make sure that all hardware is secure and tight. Optional drilling instructions. Once you have the Grille Guard installed, use the second hole, (unused up to this point), in the Frame Mounting as a template to mark the drilling location on the frame rail, (Figure 3). 3. Remove the Grille Guard, Frame s and mm Bolt and Nut Plates from the vehicle. NOTE: It is not necessary to remove Bottom or Top Support s from the vehicle. 4. Use a / drill bit to drill out the marked location, (Figure 4). IMPORTANT: Any cutting or drilling tool may break or shatter. Government regulations require safety glasses & equipment at all times when cutting or drilling. 5. Repeat steps -0 to re-install the Grille Guard onto the vehicle. NOTE: Rotate the mm Bolt and Nut Plate to line up the drilled hole with the threaded Nut. Use the included () mm x 35mm Hex Head Bolts, () mm Lock Washers, and () mm Flat Washers to secure the Frame s to the mm x 35mm Bolt and Nut Plate, (Figure 5). 6. Do periodic inspections to the installation to make sure that all hardware is secure and tight. Page 3 of 5
To protect your investment, wax this product after installing. Regular waxing is recommended to add a protective layer over the finish. Do not use any type of polish or wax that may contain abrasives that could damage the finish. For stainless steel: Aluminum polish may be used to polish small scratches and scuffs on the finish. Mild soap may be used also to clean the Grille Guard. For gloss black finishes: Mild soap may be used to clean the Grille Guard. Driver Side Installation Pictured Fig Fig 3 Fig Fig 4 Top support bracket mounting location. Insert 8mm x 5mm Bolt Plate into the factory hole from behind the radiator support Page 4 of 5
Fig 5 Fig 6 Remove this screw Driver Side Installation Pictured Reinstall the factory button head screw Insert 8mm x 5mm Bolt Plate into the factory hole from behind the radiator support Fig 7 Fig 8 Insert (-3) 8mm x6mm Flat Washers as a spacer between the Top Support and the radiator support. NOTE: It may be necessary to gently push down on the plastic grille to provide clearance for the Flat Washers/Spacer behind the Support. Secure the Support to the Bolt Plate with: 8mm Lock Washer 8mm x 6mm x.6mm Flat Washer 8mm Hex Nut Fig 9 With assistance, place the Grille Guard face down on a clean surface in front of the vehicle. Move the Grill Guard up to the outside of the Mounting. Line up the rear-most holes in the Mounting s with the Grille Guard. Insert: () mm x 35mm Hex Bolt () mm Flat Washers () mm Lock Washer () mm Hex Nut into each of the rear-most mounting holes on the driver and passenger side to act as a hinge. Tilt the Grille Guard up into position then install the remaining (4) mounting bolts. Plastic grille Page 5 of 5
Fig 0 Driver Side Installation Pictured () 8mm x 0mm Button Head Allen Bolt () 8mm x 6mm x.6mm Flat Washers () 8mm Nylon Lock Nut () 0mm x 5mm Button Head Allen Bolt () 0mm Flat Washers () 0mm Nylon Lock Nut Fig Fig Optional Drilling Instructions Fig 3 Fig 4 Page 6 of 5
Fig 5 Page 7 of 5