Fiat - 500L Trekking - Workshop Manual - 2014 - 2015

BX2803 2014-15 Fiat 500L Trekking/Easy/Pop/Lounge Installation Instructions Attachment Tab Height: 15” Serial Number Attachment Tab Width: 23” Please read BOTH these Installation Instructions and the General Instructions prior to installing or operating this equipment. 1. Blue Ox® towing products and accessories are intended to be installed by Blue Ox® Dealers who are familiar with our products and have the equipment and knowledge necessary to do “fit work”. If needed, Blue Ox® Dealers can be found at www.blueox.com or by contacting our Customer Care Department at (402) 385-3051. Bolt Torque Specifications Torque in Foot-Pounds for Inch Bolts 2. Many Blue Ox baseplates are designed to use existing holes and hardware to mount the baseplate to the towed vehicle. Even though bolts are there, do not assume they are adequate for baseplate mounting. Always use the hardware supplied in the hardware kit and existing hardware as specified in the installation instructions. ® Bolt Size Grade 5 Grade 8 1/4” 10 14 5/16” 19 29 3/8” 33 47 7/16” 54 78 1/2” 78 119 5/8” 154 230 3/4” 257 380 Bolt Torque Specifications Torque in Foot-Pounds for Metric Bolts If the front of your vehicle looks different than this, please contact us at (402)385-3051. Reference your vehicle owner’s manual for manufacturer’s towing specifications. 405-0359 Rev A Page 1 of 7 ! Bolt Size Grade 8.8 Grade 10.9 6MM 6 8 8MM 16 22 10MM 31 40 12MM 54 70 14MM 89 117 16MM 161 230 18MM 222 318 WARNING Failure to read and follow these instructions could result in separation of the towed vehicle from the tow bar, causing property damage, loss of towed vehicle, personal injury or death. 1/26/15 BX2803 2014-15 Fiat 500L Trekking/Easy/Pop/Lounge Installation Instructions Instruction Notes: The fascia and horn are removed and reinstalled for the baseplate installation. Some drilling and trimming is required. Place all components that are removed on a flat, sturdy surface. All items will be reinstalled unless otherwise noted after the baseplate is installed. The dimensional variations between otherwise identical vehicles can be considerable. While the baseplate was designed for easy installation, it may be necessary to tailor the baseplate slightly to compensate for vehicle manufacturer’s tolerances. The BX8869 Tail Light Wiring Kit is recommended for this vehicle. Drill a hole according to the tail light wiring kit instructions. NOTICE • Handling of some cosmetic parts when installing this product may require the use of protective covers, rags, specialty tools, etc. to prevent damage. • When using power drills be aware of the dangers of torque and drill bit length. • When using a reciprocating saw be aware of objects behind the cutting surface. • Use a good quality paint to spray cut edges of frame to prevent rusting. • Be sure that ALL electrical connections are plugged in and accessories are functioning properly before reinstalling the fascia. • The baseplate is computer tested to your vehicle’s GVWR, exceeding this weight will void the manufacturer’s warranty. • Be sure to use Loctite® Red on all bolts before tightening. Tighten all bolts according to the torque chart provided. • Dealer or installer be certain the user receives these instruction sheet. • If the baseplate is in an accident, it must be replaced. DO NOT use it again! An accident can cause unseen damage and using it again could result in more damage or serious injury. DO NOT use the baseplate if it is damaged or missing parts. 405-0359 Rev A Page 2 of 7 1/26/15 BX2803 2014-15 Fiat 500L Trekking/Easy/Pop/Lounge Installation Instructions Tools Required Large Vise Grip Flat Screwdriver Utility Knife Phillips Screwdriver Torque Wrench Drill Tape Measure Loctite® RED 13/32” Drill Bit 10MM Socket 15MM Socket 9/16” Socket T27 Torx 6 BREAKAWAY SWITCH 5 14 12 1 10 2 4 3 13 9 11 4-PIN CONNECTOR 8 7 6-PIN CONNECTOR 14 Item No. Part No. Description Qty. 1.................................61-4978..............................3/8”-16 Whiz Nut w/ 14” Wire...........................................6 2.................................61-7249..............................BX2803 Baseplate............................................................1 3.................................62-3468..............................Attachment Tab Assembly with Hole................................2 4.................................101-5822............................4 Way Connector Adapter................................................2 5.................................102-7056............................Breakaway Bracket..........................................................1 6.................................201-0050............................1/4”-20 x 3/4” Hex Head Bolt, Grade 5, ZP......................1 7.................................201-0192............................#10-32 1/2” Round Slotted Head Screw...........................2 8.................................201-0443............................3/8”-16 x 1” Hex Head Bolt, Grade 5, ZP.........................6 9.................................201-0979............................#12-14 X 1” Self Drilling Screw, ZP..................................2 10...............................201-0654............................#10-16 x 1” Self Drilling Screw, ZP...................................1 11................................202-0047............................#10-32 Hex Nut................................................................2 12...............................202-0102............................1/4”-20 Hex Nylon Nut, ZP...............................................1 13...............................203-0054............................#10 Lock Washer, ZP.......................................................2 14...............................Existing...............................Existing Bumper Bolts......................................................6 15...............................226-0046(not shown).........Class III Safety Cables.....................................................2 16...............................229-0359(not shown).........3/8” Quicklink, ZP.............................................................2 17...............................290-0437(not shown).........Black Cap Plug Receiver..................................................2 Important: Use only genuine factory replacement parts on your baseplate. Do NOT substitute homemade or non-typical parts. If a bolt is lost or in need of replacement, for your safety and the preservation of your baseplate, be sure to use a replacement bolt of the same grade (In most cases it will be Grade 5, please reference the parts list above). Replacement parts may be ordered through your nearest Blue Ox® Dealer or Distributor. Failing to follow and/ or altering these installation instructions in either installation or required equipment will void the manufacturer’s warranty. Towing behind a non-motorized vehicle will void the warranty. 405-0359 Rev A Page 3 of 7 1/26/15      BX2803 2014-15 Fiat 500L Trekking/Easy/Pop/Lounge Installation Instructions  Using a T27 Torx, remove the six (6) screws from the top edge of the fascia. There are three (3) on each side. 3. Using a Philips screwdriver, remove the ten (10) screws from the underside of the fascia. There are four (4) on each corner and two (2) in the middle. 2. In the wheel well, using a Phillips screwdriver, remove the two (2) screws from the outer edge (white). Then using a T27 Torx, remove the screw from the top outer edge (gray). 4. Unsnap the fascia from each side. Unplug all electrical connections, then pull the fascia forwards from the vehicle.  405-0359 Rev A      1. Page 4 of 7 1/26/15      BX2803 2014-15 Fiat 500L Trekking/Easy/Pop/Lounge Installation Instructions  On the bumper horn, using a 15MM socket, remove the three (3) bolts (white). Then using a 10MM socket, remove the one (1) nut. Do this on both sides of the vehicle. The bumper horns will not be reinstalled, but the existing bolts will be reused. 6. Trim the plastic shrouding around the radiator as shown. Do this on both sides of the vehicle. 7. Using a 10MM socket, remove the nut from the horn bracket on the passenger side and move the horn aside. 8. Slide the baseplate onto the vehicle. Secure in place with the six (6) existing bolts (white). There are three (3) on each side and fully tighten all hardware. Using a 13/32” drill bit, drill the six (6) holes thru the frame (gray). There are three (3) on each side. Install six (6) 3/8”-13 x 1” bolts into the holes with 3/8” wire nuts on the inside of the frame and fully tighten all hardware. Page 5 of 7 1/26/15  5.      405-0359 Rev A   BX2803 2014-15 Fiat 500L Trekking/Easy/Pop/Lounge Installation Instructions 9. On the passenger side, reinstall the horn to the existing stud. 10. Attach the permanent baseplate safety cables to the provided convenience link on the baseplate. The photo above shows the recommended installation of the cables to frame of vehicle. Additional options may interfere with suggested mounting; in this case, secure the cables to a solid piece of the frame as described in the instructions included with the permanent baseplate safety cables. Be sure the safety cables do not rub against any hoses or moving parts. Do this on BOTH sides of the vehicle.   11. Optional: If installing a breakaway, measure over 5-1/4” from the slot on the driver side of the bumper. Screw the bracket to the bumper with the #10-16 self tapping screw. Install the breakaway to the bracket with a 1/4”-20 bolt and lock nut. 405-0359 Rev A 12. On the backside of the fascia, remove the wiring from the clip (white) and trim the inside edge of the fascia as shown. Do this on both sides of the fascia. Page 6 of 7 1/26/15 BX2803 2014-15 Fiat 500L Trekking/Easy/Pop/Lounge Installation Instructions   14. Hold the fascia as close to its original position, mark and trim the fascia around the convenience links and attachment tabs. Reinstall the fascia. CUSTOMER SERVICE COMMITMENT Blue Ox® is committed to providing you with exceptional customer care throughout your lifetime with our products. Our team is here to assist you with any questions you may have regarding the performance of your product. Simply call (402) 385-3051 and you can speak with our customer care team. Additionally, please visit our website to see which rallies our Destination America team will be attending. For a nominal fee, our service technician will service your towing system to ensure it’s in proper working condition. Also, as a commitment to our customers, should you visit our factory, you can stay at our full service Blue Ox® campground at no charge along with enjoying a factory tour. Again, thank you for being our customer and for the confidence you have shown in the performance of our products. It is because of customers like you we enjoy the success we have today. © 2015 Blue Ox One Mill Road, Industrial Park Pender, Nebraska 68047 Phone: (402) 385-3051 Fax: (402) 385-3360 www.blueox.com 405-0359 Rev A Page 7 of 7 1/26/15