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INSTALLATION INSTRUCTIONS SEMI-HIDDEN KIT Part Number: 103210 Application: 2015+ Chevrolet Colorado (non ZR2)

GENERAL SAFETY PRECAUTIONS

Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have provided installation and operating instructions and other information on labels and in this guide. This information alerts you to potential hazards that could hurt you or others. It is not possible to warn you about all potential hazards associated with this product, you must use your own good judgment. CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT. This guide identifies potential hazards and has important safety messages that help you and others avoid personal injury or death.

WARNING and CAUTION are signal words that identify the level of hazard. These signal words mean: WARNING signals a hazard that could cause serious injury or death, if you do not follow recommendations.

CAUTION signals a

hazard that may cause minor to moderate injury, if you do not follow recommendations. This guide uses NOTICE to call attention to important mechanical information, and Note: to emphasize general information worthy of special attention.

WARN I NG IMPACT AND MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to severe injury or death

• Always Know Your Winch. Take time to fully read the Instructions and/or Operations Guide, and/or Basic Guide to Winching Techniques, in order to understand your winch and its operations. • Never work under vehicle before properly securing vehicle. • Always use appropriate and adequate care in lifting components into place. • Never work under vehicle before properly securing vehicle. • Always use appropriate and adequate care in lifting components into place. • Never use a jack to support the vehicle. • Always use jack stands in pairs to support the vehicle. • Always use jacks or jack stands only on a hard, stable, and level surface. • Never exceed the rated capacity of a jack or jack stands. • Always verify that the parking brake is set, the transmission is in park (automatic) or reverse (manual) and the rear wheels are blocked before working on vehicle. • Never work under vehicle before properly securing vehicle. • Always use appropriate and adequate care in lifting components into place. • Always insure components will remain secure during installation and operation. • Always tighten all nuts and bolts securely, per the installation and operation. • Always perform regular inspections and maintenance on the winch, winch mount and related hardware. • Always replace all worn or damaged parts before operating. • Never operate this WARN product with damaged or missing parts. • Always use extreme caution when drilling on any vehicle. Make sure that all fuel lines, brake lines, electrical wires, and other objects are not punctured or damaged when / if drilling on the vehicle. Thoroughly inspect the area to be drilled (on both sides of material) prior to drilling, and relocate any objects that may be damaged. Failure to inspect the area to be drilled may result in vehicle damage, electrical shock, fire or personal injury. • Always use extreme caution when cutting and trimming during fitting. • Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause eye injury. • Always remove jewelry and wear eye protection. • Never lean over battery while making connections. • Never route electrical cables across any sharp edge, through or near moving parts, near parts that become hot. Read installation and operating instructions thoroughly.

WARN INDUSTRIES, INC. 12900 S.E. Capps Road, Clackamas, OR USA 97015-8903, 1-503-722-1200, FAX: 1-503-722-3000 Customer Service: 1-800-543-9276 Dealer Locator Service: 1-800-910-1122 International Sales/Customer Service: 1-503-722-3008 International Fax: 1-503-722-3005

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CAUT I ON

MOVING PARTS ENTANGLEMENT HAZARD Failure to observe these instructions could lead to minor or moderate injury

•

Part edges may be sharp!

• Always use proper posture / lifting technique or get lifting assistance while handling and installing product. Read installation and operating instructions thoroughly.

EQUIPMENT DAMAGE NOT I C E

• Never tow vehicle by attaching a tow bar to the eyelets on the bumper. • Do not attach tow bars directly to the bumper. Damage to bumper may occur. WARN bumpers are not designed to be used for flat towing. Consult with the manufacturer of your tow bar system for the proper vehicle tow bar brackets.. Read installation and operating instructions thoroughly.

NOT E S

BEFORE YOU BEGIN

This product may interfere with driver assist systems such as adaptive cruise control and parking assist systems that have sensors or cameras installed in the bumpers or front grill area. If your vehicle is equipped with any of these systems or features, consult your vehicle owner’s manual before installing this product. These systems may need to be disabled as a result of installing this product.

TABLE OF CONTENTS

Tools Required..................................................................page 2 Parts List..............................................................................page 3 Torque Specifications.....................................................page 3 Installation.......................................................................page 4-9 Maintenance/Care...........................................................page 9

TOOLS REQUIRED

• • • •

Metric socket and wrench set Standard socket and wrench set

Socket Extension

Philips Head Screwdriver

• Small Flat Head Screwdriver or body panel tool • Rolling floor jack

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PARTS LIST

Item

Description

Qty.

Item

Description

Qty.

A1 A2 A3

102879 102956 105841

SEMI HIDDEN WELDMENT

1 2 1

B1 B2 B3

69954 64108 83125

M8 10 - 1.5 x 35 FLANGE BOLT

4 3 3

NUT PLATE

M6-1.0 X 25-HEX HEAD-FLANGE BOLT

TEMPERATURE SENSOR BRACKET

M6 X 1.0 FLANGED NUT

TORQUE SPECIFICATIONS

Please use the recommended torque specifications when assembling this product unless otherwise specified in the instructions.

FASTENER SIZE

FASTENER TORQUE

FASTENER SIZE

FASTENER TORQUE

lb-ft

(N.m)

lb-ft

(N.m)

1/4"

(11)

M4 M5 M6 M8

(2)

3 6

5/16"

17 (23) 30 (40) 48 (66) 74 (100) 106 (144) 148 (200) 269 (364)

(4.5) (7.5) (18) (37)

3/8"

10 25 50

7/16”

1/2"

M10

9/16”

5/8" 3/4”

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INSTALLATION INSTRUCTIONS

1. Remove the six screws at the top of the grille using a T-15 bit.

Figure 1

2. Remove the six fender liner screws with a T-15 bit. Repeat for other side.

Fender liner bolts

3. Remove the bolt that sits behind tire and against the frame using a 7mm socket. Repeat for other side.

Frame bolt

Figure 2

4. Pull back the fender liner and remove the three bolts securing bumper fascia, using a 7mm socket. Repeat for other side.

5. Unplug fog lights if equipped. Repeat for other side.

Unplug fog lights

Figure 3

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INSTALLATION INSTRUCTIONS

6. Remove the two bolts from the front center vents with a 10mm socket. NOTE: They are only accessible with an extension. Repeat for other side. 7. From underneath the truck, looking towards the front, remove the four screws (two on each side) along the bottom edge, using a T-15 bit.

CAUTION Always use assistance when moving or lifting heavy parts.

8. The bumper and grille can now be removed as one piece. With assistance, start from the edges and carefully pull bumper and grill forward and off the vehicle. NOTE: On each side, above the fog light and near the frame rail, there is a clip that must be released while under tension. Squeeze the metal ears together while an assistant pulls on the bumper.

Figure 4

Three push clips

Once the bumper and grille are free from the vehicle, set bumper face down on a flat, clean and stable surface.

9. Remove the air duct by first removing the three push clips along the top edge, and then releasing the single clip on each side as shown in the detail views.

Single clips

Figure 5

10. Using a 15mm socket, remove the four crash bar bolts and remove bumper reinforcement bar from the frame of the truck. Save hardware for reuse.

Figure 6

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INSTALLATION INSTRUCTIONS

11. Using an 18mm socket, remove the two tow hook bolts and remove the tow hook completely. Repeat for other side.

Figure 7

12. Dismount the temperature sensor bracket by pulling out at the bottom of the bracket and then down.

13. Separate the temperature sensor from the factory plastic bracket and discard bracket. NOTE: The sensor will be reinstalled with a new bracket.

Figure 8

14. Remove plastic air dam from factory bumper. a. Use a T-15 bit to remove the six screws securing the air dam reinforcement brackets. Note: You will be reinstalling brackets later. b. Remove the 13 remaining screws retaining the air dam using a T-15 bit.

Reinforcement bracket screws

Figure 9

15. Remove center plastic valance by releasing the 12 retaining clips.

16. Reinstall the reinforcement brackets.

Figure 10

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INSTALLATION INSTRUCTIONS

17. With the winch and mount close to the front of the vehicle, route the winch power cables up toward the engine bay.

NOTE: Make sure to route wires/cables away from sharp edges, heat and moving parts.

Figure 11

18. Continue routing the cables through the hole behind the driver side headlight, around the washer fluid reservoir and towards the vehicle battery.

Figure 12

19. Insert a nut plate (A2) into each frame rail as shown. NOTE: Ensure that the nut plate aligns with the existing holes in the mounting pad. Repeat for other side.

Figure 13

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INSTALLATION INSTRUCTIONS

20. Snap the factory temperature sensor into the larger hole of the new temperature sensor bracket (A3). 21. Install sensor / bracket assembly to original mounting location on the inner grille using one M6 bolt (B2) and nut (B3). NOTE: Bracket not shown to clarify location of bolt hole and sensor.

CAUTION Always use assistance when moving or lifting heavy parts.

22. Reinstall the stock bumper ( without air dam and center valance ). NOTE: Ensure that the winch power cables pass through the opening left by the center valance.

Figure 14

23. Install fairlead to winch mount.

24. Install winch to mount following your winch installation instructions.

TIP: We recommend using a rolling floor jack or similar for winch mount to vehicle installation.

25. Slide the winch mount in and up into position ( be sure to clear the control pack on winch ).

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INSTALLATION INSTRUCTIONS

26. Using the factory bumper reinforcement bar hardware, secure winch mount in the original reinforcement bar mounting holes. Repeat for other side.

27. Using bolts (B1) secure winch mount to vehicle frame rail and into nut plates. NOTE: It will be easiest to access the bolts through the access ports in the front of the winch mount. The bolts are shown below with the stock bumper removed for clarity. Repeat for other side.

Factory bolts

28. Tighten all hardware to proper torque specifications. Your installation is now complete.

MAINTENANCE / CARE 1. Inspect all parts on the winch, winch mount, and related hardware prior to each use. Replace all hardware that appears rusted or deformed. 2. Inspect all nuts and bolts on the winch, winch mount,, and related hardware prior to each use. Tighten all nuts that appear to be

loose. Stripped, fractured, or bent bolts or nuts need to be replaced. 3. Check all cables prior to use. Replace cables that look worn or frayed. 4. Check all moving or rotating parts. Remove debris that may inhibit the part from moving freely.

CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE. READ AND UNDER- STAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE INSTALLING AND OPERATING THIS PRODUCT.

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