Westin Sportsman 40-0125 User manual

STEP 1.
STEP 2.
Remove the contents from box and check for damage. Verify all parts are present. Read instructions completely
before beginning.
Attach light guard assemblies as shown.
Center and level Sportsman on vehicle and tighten all fasteners. Recommended torque values are 43 Ft. Lbs. for 1/2”
stainless fasteners.
SEE FIGURE 1.
STEP 3.
STEP 4.
STEP 5.
STEP 6.
STEP 7.
STEP 8.
STEP 9.
STEP10.
To install mount brackets, removal of bumper/grille is necessary. Remove seven Phillips screws from grille, (four above
grille, and three on lower front of grille) (Figure 2A). Remove (2) 10mm bolts from bumper, located at front/inside of
fender, using nut driver (Figure 2B). Cut out (6) plastic rivets from inside of front fender, three on each side (replace-
ments provided). From beneath vehicle, remove three pin retainers from bottom/center of bumper with flat screw-
driver and disconnect fog lamp connector, (if equipped)(Figure 2C). Pull bumper/grille straight out from vehicle.
Install mount brackets to frame using 1/2" and 3/8" hardware as shown in Figure 2. Finger tighten so brackets move
freely. Repeat for opposite side.
Measure distance from inside to inside of Sportsman uprights near slots. Center mount brackets on vehicle so that this
distance is the outside to outside measurement of the mounting brackets.
Make sure brackets are properly aligned and tighten fasteners. Recommended torque values are 64 Ft.Lbs. for 1/2”
fasteners and 26 ft. lbs. for 3/8" fasteners.
Replace bumper/grille in opposite order of removal. (Step 3). Use the replacement, plastic “push-type” retainers
provided.
Place cardboard under front side of vehicle. Lay Sportsman on cardboard with front side down. Slide Sportsman
back so that the rearmost slots align with the rearmost slots on the brackets. Attach Sportsman to brackets at rearmost
slots using 1/2” stainless steel black zinc fasteners provided.
Carefully rotate Sportsman up toward vehicle until remaining slots are aligned. Insert remaining 1/2" fasteners. Do not
tighten at this time.
INSTALLATION INSTRUCTIONS
APPLICATION: 1999-04 JEEP GRAND CHEROKEE/LAREDO 2/4
WHEEL DRIVE
1999-03 JEEP GRAND CHEROKEE LIMITED
SPORTSMAN
ASSEMBLY
40-0125
AUTOMOTIVE PRODUCTS, INC.
PARTS KIT CONTENTS
ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION
TOOLS REQUIRED
3/4” SOCKET 3/4” WRENCH 9/16” SOCKET 9/16” WRENCH 7/16” WRENCH
5/32” HEX WRENCH 19MM SOCKET 10MM NUT DRIVER RATCHET TAPE MEASURE
TORQUE WRENCH UTILITY KNIFE PHILLIPS SCREWDRIVERFLAT TIP SCREWDRIVER
SPORTSMAN ASSEMBLY
LIGHT GUARD ASSEMBLY
MOUNT BRACKET, PASSENGER (4) AND DRIVER (5)
1/2-13 X 1.25” HEX HEAD BOLT, BLACK ZINC
1/2” FLAT WASHER, BLACK ZINC
1/2” LOCK WASHER, BLACK ZINC
1/2-13 HEX NUT, BLACK ZINC
1/2-13 X 1.25” HEX HEAD BOLT
, PASSENGER (2) AND DRIVER (3)
1/2” SAE SMALL O.D. FLAT WASHER
1/2” USS LARGE O.D. FLAT WASHER
1/2” WILLIAMS WASHER (THICKEST WASHER)
1/2” LOCK WASHER
1/2-13 HEX NUT
3/8-16 X 1.25” HEX HEAD BOLT
3/8” FLAT WASHER
3/8” LOCK WASHER
3/8-16 HEX NUT
PLASTIC PUSH PIN
2
2
2
2
4
8
4
4
8
12
13
14
15
16
17
18
19
20
1
2,3
4,5
6
7
8
9
10
11
1
2
2
6
12
6
6
2
2
1
2
45
3
75-0226 Revision D 3/14/07
WO:

14
11
7
79
17
18
12
10
6
8
16
13
5
17
15
19
Finish protection - Westin products have a high quality finish that must be cared for like any
other exposed finish on the vehicle. Protect the finish with a non-abrasive automotive wax (pure
carnauba, for example) on a regular basis. The use of cleaner wax or any compound which
contains an abrasive is detrimental, as the compounds scratch the finish and open it to
corrosion.
Westin Automotive Products, Inc.
5200 N. Irwindale Ave. Suite 220
Irwindale, Ca. 91706
Thank You for choosing Westin products
For aditional installation assistance please call
Customer service [phone] or [phone]
10mm BOLT
PLASTIC PUSH PIN FOG LAMP
CONNECTOR
PLASTIC RIVET
PHILLIPS SCREW
BUMPER/GRILLE ASSY
FORWARDFORWARD
SPORTSMAN ASSY
FIGURE 3
DRIVER SIDE SHOWN
FIGURE 3
DRIVER SIDE SHOWN
FIGURE 2AFIGURE 2A
FIGURE 2BFIGURE 2B
FIGURE 2CFIGURE 2C
2
2
4
4
5
1
2
13
13
1
2
5
ITEM QTY. DESCRIPTION
1 8 1/4-20 X 1.00” BUTTON HEAD BOLT
2 8 1/4” FLAT WASHER
3 4 1/4” INTERNAL TOOTH LOCK WASHER
4 4 1/4-20 NYLON NUT
5 8 RUBBER WASHER
NOTE: ALL FASTENERS MAY NOT BE USED.
FIGURE 1